Tooling for and Method of Fabricating Master Models

In making master models for large complex shaped parts it is common practice to use a series of headers each accurately machined and accurately located. A filler material is then placed between the headers and the exterior contoured using the headers as reference. Header alignment is normally accomplished by use of optical instruments. These instruments provide alignment to a high degree of accuracy, however, it requires highly skilled personnel and is time consuming. It was found the headers can be aligned, by the use of new tooling, to the same high degree of accuracy, and it can be accomplished with a considerable time savings while using less skilled personnel by practicing the art of this invention.

A base surface is machined flat to a close tolerance and is leveled. A pair of index bars are secured to the base with the bars parallel to each other and one of the bars having one side acting as a buttock line. The bars also have matching indexing along the length for identifying and scribing header locations on the base.

FIG. 1 shows a perspective view of the tooling of this invention with headers of a master model positioned.

FIG. 2 shows an end elevational view of FIG. 1.

FIG. 3 shows a side elevational view of FIG. 1.

FIG 4 shows a plan view of FIG. 1.

FIG. 5 shows a plan view of the tooling of this invention.

FIG. 6 shows a perspective view of a header station gage.

FIG. 7 shows a perspective view of a different embodiment of the tooling of this invention, with headers of a master model positioned.

FIG. 8 shows an end elevational view of FIG. 7.

Tooling 10 for a master model alignment uses a base 12, a pair of indexing bars 14aand 14b, and a vertical alignment member 16. The top surface 18, of the base must be machined to close tolerance, and that surface leveled preferably to within 0.002 inches to form the base line plane for the tooling. Index bar 14a has vertical side 20, which is machined to a close tolerance, preferably of 0.002 inches to act as a buttock line and or plane. The opposite side 22 is machined to the same tolerance and is parallel to side 20. This bar has a series of holes 24a, which are laid out along a line parallel to the buttock line. These holes are arranged at carefully controlled distances from each other to provide indexing along the length. The second index bar 14b, also has a series of holes 24b, set out along a line parallel to the buttock line. These holes are arranged to match the alignment of the holes in index bar 14a, and each pair of aligned holes in the two bars lie along a line that is perpendicular to the buttock line.

The vertical alignment member 16 may use precision cubes, angles, or sine plates, acting as a pattern, but in this view an angle is used. The angle is shaped such that surface 26 extends vertically from the base plane and perpendicular to the buttock line with side 28 abutting side 22 of index bar 14a. A flat rod 30 is secured to the surface 26 of the vertical alignment member 16 and extends out along a line parallel to the surface of the base and as on extension of surface 26.

A header station gage 32b, has a support member 34, with an elongated slot 36, and a series of in line holes 38. The holes and the slot are all in line and are used in combination with pins 40a and 40b to quick connect securing of the gage to the indexed holes in the index bar 14b. An adjustable curved contact head 42 is located on the support member. That head can be adjusted with respect to the hole locations 38, to permit accurate measurement from the indexed hole locations on the index bar.

A series of headers 44, are each individually contoured with respect to a part 46 of the header, located for contacting the base, and a part 48 of the header, located for contacting the side 20, of the index bar, representing the buttock line.

In using the tooling 10, for aligning the headers 44 one sets up and starts using the tooling as is shown in FIG. 5. The two index bars 24a and 24b are secured to surface 18 of the base 12 with the bars and the holes 24a and 24b of those bars aligned with respect to each other. A pair of header station gages 32a and 32b are placed on the index bars and the curved contact heads 42 adjusted to define an edge of a header location. A bar 50 extends between the two bars. That bar has parallel surfaces along opposite sides that are machined to close tolerances. The bar is held against the contact heads and used as a guide to scribe the header line 52, on the base. Each header location is scribed in this manner. Angle irons 54 are placed along the scribed lines and are then secured to the base. The headers 44 are then positioned against the angle iron with part 46 resting on the base and part 48 abutting against buttock line reference 20, and the header is then secured to the angle iron. The vertical alignment member 16 is then placed in position on the base and along the scribe line with side 28 abutting side 22 of the index bar 14a. The surface of the header is then brought up against flat rod 30 and the header is held in that position with rod 56 and nuts 58. This serves to align the headers vertically.

FIGS. 7 and 8 show a different embodiment where an index bar 59, having an accurate side 60 to act as a buttock line, is located on an accurately machined and leveled base 62, and the buttock line is located to contact an interior surface 64 of headers 66. These headers are each machined in reference to the surfaces 68 contacting the base, and the buttock referenced interior surface. An additional pair of index bars 70a and 70b are located on the base and alongside the headers. These additional bars each have a row of in line indexing holes 72a and 72b which are aligned parallel to the buttock line, match each other and are aligned with matching pairs of holes extending perpendicular to the buttock line.

In this embodiment the three indexing bars are aligned and secured to the base. A pair of header station gages 32 are used as before in conjunction with index bars 70a and 70b to scribe header locations on the base. Angle irons 74 are then located along the scribe lines, the headers 66 positioned to contact the angle irons, the base and the buttock line reference 60, and the headers secured to the angle iron. These headers may be vertically aligned as before, however, if the headers are long it is preferable to vertically align using an optical instrument 76. This optical instrument is preferably mounted on a structure 78, that has a track 80 that is leveled and that extends parallel to the buttock line as indicated by side 60 of index bar 59. This provides for moving the instrument to a position to sight in and set the vertical alignment and the headers are then secured in position with threaded bars 82 and nuts 84.