Pot broaching tools and methods for remanufacture-forming pot broaching tools

Abstract

A remanufactured pot broaching tool includes an elongated bar with a cutting side and a bottom side spaced part from the cutting side. A milled shim is cool laser bonded to the bottom side of the elongated bar. The milled shim has a thickness between 0.0625 inches and 0.500 inches and a flatness tolerance within +0/−0.0002 inches. A tolerance of a height dimension of the remanufactured pot broaching tool between an outer surface of a set of teeth on the cutting side and the outer elongated surface of the milled shim cool laser welded to the bottom side of the elongated bar is +0/−0.0002 inches.

1 . A remanufactured pot broaching tool comprising:
 an elongated bar comprising a cutting side with a set of cutting teeth and a bottom side spaced apart from the cutting side;   a rough milled shim; and   a cool laser weld between the bottom side of the elongated bar and the rough milled shim such that the rough milled shim is bonded to the elongated bar, wherein the milled shim comprises an outer elongated surface with a flatness tolerance within +0/−0.0002 inches.   
     
     
         2 . The remanufactured pot broaching tool of  claim 1 , wherein a tolerance of a height dimension between an outer surface of the set of teeth and the outer elongated surface of the milled shim is within +0/−0.0002 inches. 
     
     
         3 . The remanufactured pot broaching tool of  claim 1 , wherein the milled shim comprises a rough milled inner surface in contact with the bottom side of the elongated bar. 
     
     
         4 . The remanufactured pot broaching tool of  claim 3 , wherein the rough milled inner surface has an Ra surface finish between 250 and 30 μin. 
     
     
         5 . The remanufactured pot broaching tool of  claim 1 , wherein the milled shim has a thickness between 0.0625 inches and 0.500 inches. 
     
     
         6 . The remanufactured pot broaching tool of  claim 1  further comprising a cylindrical walled pot, wherein the elongated bar with the milled shim cool laser welded to the bottom side of the elongated bar is rigidly attached to an inner surface of the cylindrical walled pot. 
     
     
         7 . The remanufactured pot broaching tool of  claim 1 , wherein the set of cutting teeth is a set of re-ground cutting teeth. 
     
     
         8 . A pot for a broaching machine comprising:
 a cylindrical walled pot; and   a set of pot broaching tools positioned and aligned within the cylindrical walled pot;   wherein:   each of the set of pot broaching tools comprises an elongated bar, cutting teeth extending from a cutting side of the elongated bar, and a bottom side spaced part from the cutting side; and   at least one of the set of pot broaching tools is a remanufactured pot broaching tool with re-ground cutting teeth, a rough milled shim cool laser welded to the bottom side of the elongated bar, and an outer elongated surface of the rough milled shim has a flatness tolerance within +0/−0.0002 inches.   
     
     
         9 . The pot broaching machine of  claim 8 , wherein a tolerance of a height dimension between an outer surface of the set of teeth of the remanufactured elongated bar and an outer elongated surface of the milled shim is +0/−0.0002 inches. 
     
     
         10 . The pot broaching machine of  claim 8 , wherein the milled shim comprises a rough milled inner surface in contact with the bottom side of the elongated bar. 
     
     
         11 . The pot broaching machine of  claim 8 , wherein the milled shim has a thickness between 0.0625 inches and 0.25 inches. 
     
     
         12 . A method for replacing pot broaching tools in a pot broaching machine, the method comprising:
 removing a pot containing a set of broaching tools from a pot broaching machine;   replacing a first set of pot broaching tools from the pot with a second set of pot broaching tools, wherein the second set of pot broaching tools comprise at least one remanufactured pot broaching tool, the at least one remanufactured pot broaching tool formed by re-grinding cutting teeth on a cutting side of the pot broaching tool, cool laser welding a rough milled shim to a bottom side of the pot broaching tool, and grinding the cool laser welded rough milled shim such that an outer surface of the cool laser welded milled shim has a high polished surface; and   re-installing the pot into the pot broaching machine.   
     
     
         13 . The method of  claim 12 , wherein the at least one remanufactured pot broaching tool is installed within the pot without the use of a thin shim between the milled shim cool laser welded to the bottom side of the pot broaching tool and an inner surface of the pot. 
     
     
         14 . The method of  claim 12 , wherein the at least one remanufactured pot broaching tool comprises a set of remanufactured pot broaching tools and the set of remanufactured pot broaching tools are installed within the pot without the use of thin shims between the milled shims cool laser welded to the bottom sides of the set of pot broaching tools and an inner surface of the pot. 
     
     
         15 . The method of  claim 14 , wherein a time to replace the first set of pot broaching tools with the second set of pot broaching tools using the set of remanufactured pot broaching tools without the use of thins shims is reduced by at least  50 % compared to replacing the first set of pot broaching tools with remanufactured pot broaching tools and thin shims between the remanufactured pot broaching tools and the inner surface of the pot. 
     
     
         16 . The method of  claim 12 , wherein the at least one remanufactured pot broaching tool has a tolerance of a height dimension between an outer surface of the set of cutting teeth and an elongated outer surface of the cool laser welded milled shim within +0/−0.0002 inches. 
     
     
         17 . The method of  claim 14 , wherein the milled shim comprises a milled inner surface in contact with the bottom side of the elongated bar.