Vibration-assisted drilling system and method of use

Abstract

The present invention is entitled "Vibration-Assisted Drilling System and Method of Use." A vibration-assisted drilling system is provided. The vibration-assisted drilling system includes: a drill feed motion system having a drill feed axis; an oscillating motion system having an oscillating axis; a drill spindle having a drill bit; and a mounting system configured to connect the drill spindle to the oscillating motion system. The drill feed axis is substantially parallel to and offset from the oscillating axis.

Description

Technical field:

[0001] The present disclosure relates generally to drilling, and more particularly to vibration-assisted drilling (VAD). Background technology:

[0002] Drilling and fastening are steps in the assembly process for many different types of structures. Some structures are formed from more than one type of material. Drilling can be performed through mixed material stacks (e.g., layers of metal and composite materials). Drilling mixed material stacks can be undesirably time-consuming, which limits production processes and throughput rates.

[0003] During conventional drilling, the drill bit is driven toward the workpiece as it rotates. During conventional drilling, the drill bit maintains contact with the workpiece material. Conventional drilling processes can produce chips of varying sizes. These chips can include long, coiled chips. In some illustrative examples, the chips can become entangled around the drill bit. While entangled around the drill bit, the chips rotate within the drill hole, pulling material from the workpiece.

[0004] Conventional drilling generates friction, heating both the drill bit and the workpiece.In some illustrative examples, conventional drilling generates undesirable heat in the workpiece.

[0005] Therefore, it would be desirable to have methods and apparatus that take into account at least some of the issues discussed above, as well as other possible issues. Summary of the invention:

[0006] Examples of the present disclosure provide a vibration-assisted drilling system. The vibration-assisted drilling system includes a drill feed motion system having a drill feed axis, an oscillating motion system having an oscillating axis, a drill spindle having a drill bit, and a mounting system configured to connect the drill spindle to the oscillating motion system. The drill feed axis is substantially parallel to and offset from the oscillating axis.

[0007] Another example of the present disclosure provides a vibration-assisted drilling system. The vibration-assisted drilling system includes a drill feed motion system having a servo system and multiple linear guides, an oscillating motion system having an actuator and an oscillating shaft, and a drill spindle having a drill bit. The drill spindle is mounted to the oscillating motion system. The drill feed motion system includes a drill feed shaft, and the oscillating shaft is separate from the drill feed shaft.

[0008] A method for performing vibration-assisted drilling is disclosed. A drill spindle is moved toward a material by a drill feed motion system having a drill feed axis. As the drill spindle advances toward the material, a drill bit of the drill spindle is rotated. The drill spindle is oscillated toward and away from the material by an oscillating motion system, wherein the oscillating motion system has an oscillation axis that is substantially parallel to and offset from the drill feed axis, and wherein the oscillating motion system couples the drill spindle to the drill feed motion system.

[0009] The features and functions can be implemented independently in various examples of the present disclosure or may be combined in still other examples, in which further details can be seen with reference to the following description and drawings. Description of the drawings:

[0010] The novel features which are believed to be characteristic of the illustrative examples are set forth in the appended claims. However, the illustrative examples, their preferred modes of use, further objects and features will be best understood by reference to the following detailed description of illustrative examples of the disclosure when read in conjunction with the accompanying drawings, in which:

[0011] Figure 1 is an illustration of a block diagram of a manufacturing environment in which the illustrative examples may be implemented;

[0012] Figure 2 is an illustration of a perspective view of a vibration-assisted drilling system according to an illustrative example;

[0013] Figure 3 is an illustration of a side view of a vibration-assisted drilling system according to an illustrative example.

[0014] Figure 4 is an illustration of an exploded view of a vibration-assisted drilling system according to an illustrative example.

[0015] Figure 5 is an illustration of a cross-sectional view of a drill bit of a vibration-assisted drilling system in a hole according to an illustrative example;

[0016] Figure 6 is an illustration of a perspective view of drilling debris according to an illustrative example.

[0017] Figure 7 is an illustration of a flow chart of a method of performing vibration-assisted drilling according to an illustrative example;

[0018] Figure 8 is an illustration in block diagram form of an aircraft manufacturing and service method according to an illustrative example; and

[0019] Figure 9 is an illustration of an aircraft in block diagram form in which illustrative examples may be implemented. Specific implementation method:

[0020] The illustrative examples recognize and take into account one or more different considerations. The illustrative examples recognize and take into account that drilling metal may result in long chips. Large drilling debris, such as long spiral ribbons or large chips, may cause scratches at the hole wall. The illustrative examples recognize and take into account that large chips may also cause at least one of the following: generate additional friction and excess heat, damage the hole surface and increase roughness, change the hole diameter, which may affect performance, or cause unreliable chip extraction.

[0021] The illustrative examples recognize and take into account that fully retracting pecking significantly increases processing time, which limits automation and rate capabilities. The illustrative examples recognize and take into account that conventional drilling processes can result in debris of varying sizes. The debris can include long, coiled debris. Conventional drilling can result in debris weighing in the range of about 20 mg to about 70 mg.

[0022] The illustrative examples recognize and take into account that vibration assisted drilling (VAD) is being investigated to control drill cuttings size. The illustrative examples recognize and take into account that vibration assisted drilling (VAD) results in lower drilling temperatures than conventional drilling.

[0023] The illustrative examples recognize and take into account that in some vibration-assisted drilling devices, the drill feed and oscillation motion are provided by a single servo motor. In these illustrative examples, the drill feed and oscillation motion are on the same axis. The oscillation frequency is limited by the servo motor response time. The illustrative examples recognize and take into account that in some vibration-assisted drilling devices, oscillations exist within the drill spindle. The illustrative examples recognize and take into account that the size and type of the vibration system within the drill spindle are limited.

[0024] Now go to Figure 1 , depicts an illustration of a block diagram of a manufacturing environment in which illustrative examples may be implemented. Manufacturing environment 100 includes a vibration-assisted drilling system 102 configured to perform vibration-assisted drilling (VAD) on a material 104. Vibration-assisted drilling system 102 includes a drill feed motion system 106 having a drill feed axis 108, an oscillating motion system 110 having an oscillating axis 112, a drill spindle 114 having a drill bit 116, and a mounting system 118 configured to connect drill spindle 114 to oscillating motion system 110. Drill feed axis 108 is substantially parallel to and offset from oscillating axis 112.

[0025] In the vibration-assisted drilling system 102, feed oscillation is independent of the main drill feed. The drill feed motion system 106 includes a plurality of linear guides 120 connected to a base 122. The drill feed motion system 106 moves the oscillating motion system 110 and the drill spindle 114 along the plurality of linear guides 120 to provide drill feed of the drill bit 116. The servo system 124 of the drill feed motion system 106 provides movement of the drill spindle 114 in the drill feed direction. The servo system 124 controls the drill feed speed 126 and moves a plurality of bearing carts 128 along the drill feed axis 108 on the plurality of linear guides 120. The linear bearing carts - the plurality of bearing carts 128 - on the guides - the plurality of linear guides 120 - are capable of handling the bending movement caused by the drilling end effector including the drill spindle 114.

[0026] The drill feed rate 126 is the speed at which the drill bit 116 is directed toward the material 104. The drill feed rate 126 is set based on the desired operation. The drill feed rate 126 is limited by the capabilities of the servo system 124. The servo system 124 is a motor that includes control circuitry and a shaft.

[0027] Oscillating motion system 110 is connected to a plurality of bearing carts 128 of drill feed motion system 106. Oscillating motion system 110 includes a sliding surface 130 and an actuator 132 having an oscillating axis 112. Sliding surface 130 is a mechanical system configured to allow movement along a single axis. In some illustrative examples, sliding surface 130 includes a plurality of linear guides 134 and a plurality of bearing carts 136. The linear bearing carts 136 on the guides 134 are capable of handling bending movements caused by a drilling end effector, including drill spindle 114.

[0028] Actuator 132 moves a plurality of bearing carts 136 along a plurality of linear guides 134. Actuator 132 can take any desired form. In some illustrative examples, actuator 132 is one of electromagnetic 138, mechanical 140, or hydraulic 142. Actuator 132 provides an oscillation velocity 144 to a plurality of bearing carts 136 and components connected thereto. Actuator 132 can have an oscillation velocity 144 that is greater than a maximum value of drill feed speed 126 of drill feed motion system 106.

[0029] The specifications of oscillating motion system 110 are determined based on the specifications of drilled hole 154 in material 104. For example, the desired specifications of oscillating motion system 110 may be influenced by the type of material 104, the thickness of material 104, the size of hole 154, the sequence of layers in material 104, or other characteristics of the drilling process. In some illustrative examples, the diameter of hole 154 is in the range of 0.25 inches to 0.875 inches. In some illustrative examples, the oscillation amplitude of actuator 132 is in the range of 0.06 mm to 0.20 mm. In some illustrative examples, the oscillation amplitude of actuator 132 is in the range of 0.06 mm to 0.16 mm. In some illustrative examples, the oscillation frequency is desirably up to 100 Hz. In some illustrative examples, the oscillation frequency is in the range of 25 Hz to 80 Hz.

[0030] In the vibration-assisted drilling system 102, a mounting system 118 mounts a drill spindle 114 to a plurality of bearing carts 136. A servo system 124 drives the plurality of bearing carts 128 toward the material 104 to provide a drill feed speed 126 to the drill spindle 114. As the drill feed motion system 106 provides movement of the drill spindle 114 toward the material 104, the drill bit 116 rotates.

[0031] As the drill spindle 114 is driven toward the material 104 by movement of the plurality of bearing carts 128, the drill spindle 114 is driven toward and away from the material 104 in an oscillating or "pecking" motion by movement of the plurality of bearing carts 136. The plurality of bearing carts 136 are driven in an oscillating manner by the actuator 132.

[0032] The drill feed motion of the drill spindle 114 provided by the drill feed motion system 106 and the oscillatory motion of the drill spindle 114 provided by the oscillatory motion system 110 provide a greater oscillation speed. A controller 146 is configured to control at least one of the servo system 124, the actuator 132, or the rotary actuator of the drill bit 116. The controller 146 is configured to synchronize the oscillation speed 144 of the oscillatory motion system 110 with the rotational speed 148 of the drill head 116 of the drill spindle 114. In some illustrative examples, the rotational speed 148 is referred to as the RPM (rotations per minute) provided by the drill spindle 114. In some illustrative examples, the RPM of the drill spindle 114 is as high as 8,000 RPM.

[0033] By synchronizing the oscillation speed 144 and the rotational speed 148, the chip size 150 of the drilling debris 152 generated by the vibration-assisted drilling system 102 is controlled. The vibration-assisted drilling system 102 drills a hole 154 and generates drilling debris 152 having the chip size 150. The chip size 150 is configured to provide reliable removal of the drilling debris 152. In some illustrative examples, the chip size 150 is smaller than drilling debris generated by conventional drilling operations. In some illustrative examples, the chip size 150 weighs less than 5 mg. In some illustrative examples, the tolerance of the chip size 150 is + / - 1 mg.

[0034] The vibration-assisted drilling system 102 includes a drill feed motion system 106 having a servo system 124 and a plurality of linear guides 120; an oscillating motion system 110 having an actuator 132 and an oscillating shaft 112; and a drill spindle 114 having a drill bit 116, the drill spindle 114 being mounted to the oscillating motion system 110. The drill feed motion system 106 has a drill feed shaft 108, and the oscillating shaft 112 is separate from the drill feed shaft 108. In the vibration-assisted drilling system 102, the oscillating motion system 110 further includes a sliding surface 130.

[0035] In some illustrative examples, the drill thrust load supplied by vibration-assisted drilling system 102 is up to 500 lb. The drill thrust load limit is affected by the robotic platform connected to assisted drilling system 102 .

[0036] Figure 1 The illustration of the manufacturing environment 100 in FIG. 1 is not meant to imply physical or architectural limitations on the manner in which the illustrative examples may be implemented. Components other than or in place of the components shown may be used. Some components may not be necessary. In addition, blocks are provided to illustrate some functional components. When implemented in the illustrative examples, one or more of these blocks may be combined, separated, or combined and separated into different blocks. For example, the sliding surface 130 may take the form of another type of mechanical movement system other than the plurality of linear guides 134 and the plurality of bearing carts 136.

[0037] As another illustrative example, sensors associated with the drill spindle 114 , the oscillating motion system 110 , and the drill feed motion system 106 are not depicted, but may be present for process monitoring and process control.

[0038] Now go to Figure 2 , depicts an illustration of a perspective view of a vibration-assisted drilling system according to an illustrative example. The vibration-assisted drilling system 200 is Figure 1 Physical implementation of the vibration-assisted drilling system 102.

[0039] The vibration-assisted drilling system 200 includes a drill feed motion system 202 , an oscillating motion system 204 , a drill spindle 206 having a drill bit 208 , and a mounting system (not depicted) configured to connect the drill spindle 206 to the oscillating motion system 204 .

[0040] In the vibration-assisted drilling system 200, feed oscillation is independent of the main drill feed. The drill feed motion system 202 includes a plurality of linear guides 210 connected to a base 212. The drill feed motion system 202 moves the oscillating motion system 204 and the drill spindle 206 along the plurality of linear guides 210 to provide drill feed for the drill bit 208. A servo system (not depicted) of the drill feed motion system 202 provides movement of the drill spindle 206 in a drill feed direction 214. The servo system controls the drill feed speed and moves a plurality of bearing carts 216 along the plurality of linear guides 210.

[0041] Oscillating motion system 204 is connected to a plurality of bearing carts 216 of drill feed motion system 202. Oscillating motion system 204 includes a sliding surface 218 and an actuator 220. Sliding surface 218 is a mechanical system configured to allow movement along a single axis. In some illustrative examples, sliding surface 218 includes a plurality of linear guides 222 and a plurality of bearing carts 224.

[0042] Now turn Figure 3 , depicts an illustration of a side view of a vibration assisted drilling system according to an illustrative example. View 300 is Figure 2 A side view of a vibration-assisted drilling system 200 is shown.

[0043] In view 300 of the vibration-assisted drilling system 200, a drill feed axis 302 and an oscillation axis 304 are indicated. The drill feed motion system 202 includes the drill feed axis 302. The drill feed axis 302 is the axis along which the plurality of bearing carts 216 move. The oscillation motion system 204 includes the oscillation axis 304. The drill feed axis 302 is substantially parallel to and offset from the oscillation axis 304.

[0044] Now go to Figure 4 , depicts an exploded view of a vibration assisted drilling system according to an illustrative example. View 400 is Figure 2 FIG4 is an exploded view of vibration assisted drilling system 200 of FIG4. In view 400 , the servo system of drill feed motion system 202 is not depicted. In some illustrative examples, a servo motor (not depicted) is coupled to a drive attached to linear guide 210 .

[0045] Figure 2-4The illustration of the vibration-assisted drilling system 200 is not meant to imply physical or architectural limitations to the manner in which the illustrative examples may be implemented. Other components may be used in addition to or in place of the components shown. For example, in view 400, the actuator 220, the plurality of linear guides 222, and the plurality of bearing carts 224 are part of a linear motor. In view 400, the actuator 220 takes the form of a magnetic plate of the linear motor system. In this illustrative example, the actuator 220 is electromagnetic. The actuator 220 takes any desired form. In other, not depicted, examples, the actuator 220 is either mechanical or hydraulic. In some, not depicted, illustrative examples, the actuator 220 includes a servo system and a ballscrew drive assembly that is connected to the plurality of bearing carts 224 of the oscillating motion system 204. Additionally, the vibration-assisted drilling system 200 is not to scale.

[0046] Now go to Figure 5 , an illustration of a cross-sectional view of a drill bit of a vibration assisted drilling system in a hole is depicted, according to an illustrative example. View 500 is a cross-sectional view of a drill bit 502 within a hole 504 of a material 506. The drill bit 502 may be Figure 1 In some illustrative examples, the drill bit 502 is physically implemented with the drill bit 116. Figure 2-4 The drill bit 208 is the same.

[0047] As the drill bit 502 rotates, the blades 508 and 510 remove drilling debris from the material 506, e.g. Figure 6 Each of blade 508 and blade 510 will remove its own cuttings. Portion 512 will be removed by one of blades 508 or 510 along cutting path 514. Portion 516 will be removed by the other of blades 508 or 510 along cutting path 518.

[0048] Now go to Figure 6 , depicts an illustration of a perspective view of drilling debris according to illustrative examples. In some illustrative examples, drilling debris 600 is Figure 1 In some illustrative examples, drilling debris 600 is formed by Figure 2-4 The vibration-assisted drilling system 200 generates the vibration-assisted drilling system 200. In some illustrative examples, by using Figure 5 The drill bit 502 drills the material 506 to generate drilling debris 600 .

[0049] Each chip of the drilling debris 600 has substantially the same size and shape. The size and shape of the chips of the drilling debris 600 are controlled by synchronizing the oscillation speed with the rotation speed of the drill bit. Each chip of the drilling debris 600 weighs approximately 3 mg.

[0050] Producing drill chips 600 of substantially the same size and shape and weighing less than 5 mg improves hole quality through fast and reliable chip removal. Producing drill chips 600 reduces or prevents chips in the interface.

[0051] Figure 2-6 The different components shown in Figure 1 Combination of components in or with Figure 1 or a combination of the two. Figure 2-6 Some of the components in Figure 1 Components shown in block form in the figures are illustrative examples of how they may be implemented as physical structures.

[0052] Now go to Figure 7 , depicts an illustration of a flow chart of a method for performing vibration-assisted drilling according to an illustrative example. The method 700 may be performed in the manufacturing environment 100 using the vibration-assisted drilling system 102. Figure 2-6 The method 700 can be performed by using the vibration-assisted drilling system 200. The method 700 can be performed to generate Figure 6 of drilling debris 600.

[0053] Method 700 moves a drill spindle toward a material via a drill feed motion system having a drill feed axis (operation 702). As the drill spindle is advanced toward the material, method 700 rotates a drill bit of the drill spindle (operation 704). Method 700 oscillates the drill spindle toward and away from the material via an oscillating motion system, wherein the oscillating motion system has an oscillation axis that is substantially parallel to and offset from the drill feed axis, and wherein the oscillating motion system couples the drill spindle to the drill feed motion system (operation 706). Method 700 then terminates.

[0054] In some illustrative examples, method 700 synchronizes an oscillation speed of the oscillating motion system and a rotational speed of a drill bit of the drill spindle using a controller of a vibration-assisted drilling system including a drill spindle, an oscillating motion system, and a drill feed motion system (operation 712 ).

[0055] In some illustrative examples, synchronizing the oscillation speed and the rotational speed of the drill bit while oscillating the drill spindle toward and away from the material removes drill debris having a substantially uniform chip size (operation 714). As used herein, the terms "approximately," "about," and "substantially" refer to an amount that is close to a stated amount and still performs a desired function or achieves a desired result. For example, the terms "approximately," "about," and "substantially" may refer to an amount that is within less than 10%, less than 5%, less than 1%, less than 0.1%, and less than 0.01% of a stated amount. In some illustrative examples, the substantially uniform chip size is within a tolerance of + / - 1 mg.

[0056] In some illustrative examples, 700 connects the oscillating motion system to the drill feed motion system (operation 708 ) and mounts the drill spindle to the oscillating motion system (operation 710 ).

[0057] As used herein, when used with a list of items, the phrase "at least one of" means that different combinations of one or more of the listed items may be used, and only one of each item in the list may be required. For example, "at least one of Item A, Item B, or Item C" may include, but is not limited to, Item A, Item A and Item B, or Item B. This example may also include Item A, Item B, and Item C or Item B and Item C. Of course, any combination of these items may exist. In other examples, "at least one" may be, for example, but not limited to, two of Item A; one of Item B; and ten of Item C; four of Item B and seven of Item C; or other suitable combinations. The item may be a specific object, thing, or category. In other words, any combination of items and at least one of the multiple items may be used from the list, but not all items in the list are required.

[0058] As used herein, "plurality," when used with reference to items, means one or more items.

[0059] The flowcharts and block diagrams in the depicted different examples illustrate the architecture, functions and operations of some possible implementations of the apparatus and methods in the illustrative examples. In this regard, each box in the flowchart or block diagram may represent at least one of a module, segment, function or operation or a portion of a step.

[0060] In some optional implementations of the illustrative examples, one or more functions marked in the blocks may not occur in the order marked in the figures. For example, in some cases, depending on the functions involved, two blocks shown in succession may be executed substantially simultaneously, or the blocks may sometimes be executed in reverse order. Similarly, in addition to the blocks illustrated in the flowchart or block diagram, other blocks may be added. Some blocks may be optional. For example, operations 708 and 710 may be optional.

[0061] You can Figure 8 Aircraft manufacturing and service method 800 is shown and Figure 9 Illustrative examples of the present disclosure are described in the context of the illustrated aircraft 900. Figure 8 , an illustration of an aircraft manufacturing and service method is depicted according to an illustrative example. During pre-production, aircraft manufacturing and service method 800 may include Figure 9 Specification and design 802 of the aircraft 900 and material procurement 804 .

[0062] During production, component and subassembly manufacturing 806 and system integration 808 of aircraft 900 occurs. Thereafter, aircraft 900 may be certified and delivered 810 for entry into service 812. While in service 812 with a customer, aircraft 900 is scheduled for routine maintenance and service 814, which may include modification, reconfiguration, refurbishment, or other maintenance and service.

[0063] Each of the processes of aircraft manufacturing and service method 800 may be performed or carried out by a system integrator, a third party, and / or an operator. In these examples, the operator may be a customer. For purposes of this specification, a system integrator may include, but is not limited to, any number of aircraft manufacturers and major system subcontractors; a third party may include, but is not limited to, any number of vendors, subcontractors, and suppliers; and an operator may include, for example, an airline, a leasing company, a military entity, a service organization, or the like.

[0064] Now refer to Figure 9 , depicts a diagram of an aircraft in which an illustrative example may be implemented. In this example, aircraft 900 is Figure 8 Aircraft manufacturing and service method 800 is produced and may include airframe 902 having a plurality of systems 904 and interior 906. Examples of systems 904 include one or more of propulsion system 908, electrical system 910, hydraulic system 912, and environmental system 914. Any number of other systems may be included.

[0065] Apparatuses and methods embodied herein may be employed during at least one of the stages of aircraft manufacturing and service method 800. Figure 8 One or more illustrative examples are manufactured or used during at least one of component and subassembly manufacturing 806, system integration 808, service 812, or maintenance and service 814 in aircraft 900. Aircraft 900 may include aircraft using Figure 1 The structure of the vibration-assisted drilling system 102 is assembled. Figure 1 The vibration-assisted drilling system 102 may be used during component and subassembly manufacturing 806. As an example, the method 800 may be used during component and subassembly manufacturing 806 to drill holes to assemble a structure. In some illustrative examples, the method 800 may be used during component and subassembly manufacturing 806 to drill holes to assemble a structure. Figure 1 The vibration-assisted drilling system 102 drills a structure that is a component of the aircraft 900 .

[0066] These illustrative examples provide a vibration-assisted drilling system having a drill feed axis and an oscillation axis that is parallel to and offset from the oscillation axis. The vibration-assisted drilling system of the illustrative examples provides an external oscillating feed drive for timed base chip fragmentation via micropecking. In the illustrative examples, the feed oscillation is independent of the main drill feed in the vibration-assisted drilling system.

[0067] The drill feed and oscillation motions are independently powered by introducing a sliding / oscillating table or surface between the servo system and the drill spindle. By separating the drill feed actuator from the oscillation actuator, higher oscillation frequencies can be powered. Oscillation can be controlled with a different actuator type than the drill feed servo system. By separating the drill feed actuator from the oscillation actuator, the oscillation is not constrained by the servo motor's response.

[0068] The implementation of vibration-assisted drilling (VAD) with synchronized oscillation speed and drill bit rotation speed can reduce processing time, thereby increasing production rate. Vibration-assisted drilling (VAD) with synchronized oscillation speed and drill bit rotation speed can improve hole quality through fast and reliable chip removal. The illustrative examples can also reduce thrust and torque loads. The smaller chips produced by the illustrative examples generate less friction during drilling. The consistent chip fragmentation provided by vibration-assisted drilling (VAD) with synchronized oscillation speed and drill bit rotation speed reduces process loads (thrust and torque loads). As the thrust load is reduced, less adjacent clamping force can be used in the component stack. Therefore, the illustrative examples can reduce at least one of the torque load or the clamping force.

[0069] Vibration-assisted drilling (VAD) with synchronized oscillation speed and drill bit rotation speed improves surface roughness. Vibration-assisted drilling (VAD) with synchronized oscillation speed and drill bit rotation speed improves drill bit fatigue life. Synchronizing oscillation speed and drill bit rotation speed using a controller provides monitoring of tool wear and process loads.

[0070] A vibration-assisted drilling system with an independent oscillating motion system can utilize an off-the-shelf drilling spindle for end effector integration. Using an off-the-shelf drilling spindle reduces the cost of the vibration-assisted drilling system. In some illustrative examples, at least one of the feed drive or the oscillation source is also off-the-shelf.

[0071] When the oscillating motion system is decoupled from the feed drive axis, the oscillation / sine wave motion is independent of the main feed drive motion. Therefore, the maximum oscillation frequency is no longer limited by how quickly the main feed drive (e.g., using a servo motor) can react / respond. This allows for higher maximum frequencies to be used in vibration-assisted drilling processes and reduces drilling cycle times.

[0072] By providing an oscillating motion system as an external system to the drill spindle, a wider range of oscillating actuator sizes and types are available compared to internal actuators to the drill spindle. Linear bearing carts on guide rails are an effective way to handle the bending motion caused by the drilling end effector.

[0073] Furthermore, the present disclosure includes implementations according to the following clauses:

[0074] Clause 1. A vibration-assisted drilling system (102), comprising:

[0075] a drill feed motion system (106) having a drill feed shaft (108);

[0076] an oscillatory motion system (110) having an oscillation axis (112), wherein the drill feed axis (108) is substantially parallel to and offset from the oscillation axis (112);

[0077] a drill spindle (114) having a drill bit (116); and

[0078] A mounting system (118) is configured to connect the drill spindle (114) to the oscillatory motion system (110).

[0079] Clause 2. The vibration-assisted drilling system (102) of clause 1, further comprising:

[0080] A controller (146) is configured to synchronize an oscillation speed (144) of the oscillatory motion system (110) and a rotational speed (148) of a drill bit (116) of a drill spindle (114).

[0081] Clause 3. The vibration-assisted drilling system (102) of clause 1 or clause 2, wherein the oscillatory motion system (110) comprises a sliding surface (130) and an actuator (132) having an oscillating axis (112).

[0082] Clause 4. The vibration-assisted drilling system (102) of clause 3, wherein the sliding surface (130) comprises a plurality of linear guides (134) and a plurality of bearing carts (136).

[0083] Clause 5. The vibration-assisted drilling system (102) of clause 4, wherein the drill spindle (114) is mounted to a plurality of bearing carts (136).

[0084] Clause 6. The vibration-assisted drilling system (102) of any of clauses 3 to 5, wherein the actuator (132) is one of electromagnetic (138), mechanical (140), or hydraulic (142).

[0085] Clause 7. The vibration-assisted drilling system (102) of any of clauses 3 to 6, wherein the actuator (132) is capable of having an oscillation speed (144) that is greater than a maximum value of the drill feed speed (126) of the drill feed motion system (106).

[0086] Clause 8. A vibration-assisted drilling system (102) according to any of clauses 1 to 7, wherein the drill feed motion system (106) includes a plurality of bearing carts (128) and a plurality of linear guides (120), wherein the oscillating motion system (110) is connected to the plurality of bearing carts (128).

[0087] Clause 9. A vibration-assisted drilling system (102), comprising:

[0088] a drill feed motion system (106) having a servo system (124) and a plurality of linear guides (120), wherein the drill feed motion system (106) has a drill feed axis (108);

[0089] an oscillatory motion system (110) having an actuator (132) and an oscillatory shaft (112), wherein the oscillatory shaft (112) is separate from the drill feed shaft (108); and

[0090] A drill spindle (114), having a drill bit (116), is mounted to the oscillating motion system (110).

[0091] Clause 10. The vibration-assisted drilling system (102) of Clause 9, wherein the oscillatory motion system (110) further comprises a sliding surface (130).

[0092] Clause 11. The vibration-assisted drilling system (102) of clause 10, wherein the sliding surface (130) comprises a plurality of linear guides (134) and a plurality of bearing carts (136).

[0093] Clause 12. The vibration-assisted drilling system (102) of any of clauses 9 to 11, wherein the actuator (132) is one of electromagnetic (138), mechanical (140), or hydraulic (142).

[0094] Clause 13. The vibration-assisted drilling system (102) of any one of clauses 9 to 12, further comprising:

[0095] A controller (146) is configured to synchronize an oscillation speed (144) of the oscillatory motion system (110) and a rotational speed (148) of a drill bit (116) of a drill spindle (114).

[0096] Clause 14. The vibration-assisted drilling system (102) of any of clauses 9 to 13, wherein the actuator (132) is capable of having an oscillation speed (144) greater than a maximum value of the drill feed speed (126) of the drill feed motion system (106).

[0097] Clause 15. A method (700) of performing vibration-assisted drilling, comprising:

[0098] moving a drill spindle (114) toward a material (104) via a drill feed motion system (106) having a drill feed shaft (108);

[0099] rotating a drill bit (116) of the drill spindle (114) as the drill spindle (114) advances toward the material (104); and

[0100] A drill spindle (114) is oscillated toward and away from a material (104) by an oscillating motion system (110), wherein the oscillating motion system (110) has an oscillation axis (112) that is substantially parallel to and offset from a drill feed axis (108), and wherein the oscillating motion system (110) connects the drill spindle (114) to the drill feed motion system (106).

[0101] Clause 16. The method (700) of clause 15, further comprising:

[0102] An oscillation speed (144) of an oscillating motion system (110) and a rotational speed (148) of a drill bit (116) of a drill spindle (114) are synchronized using a controller (146) of a vibration-assisted drilling system (102) comprising a drill spindle (114), an oscillating motion system (110), and a drill feed motion system (106).

[0103] Clause 17. The method (700) of clause 16, wherein synchronizing an oscillation speed (144) and a rotational speed (148) of the drill bit (116) while oscillating the drill spindle (114) toward and away from the material (104) removes drilling debris (152) having a substantially uniform chip size (150).

[0104] Clause 18. The method (700) of any one of clauses 15 to 17, further comprising:

[0105] connecting the oscillating motion system (110) to the drill feed motion system (106); and

[0106] The drill spindle (114) is mounted to the oscillating motion system (110).

[0107] Clause 19. The method (700) of any of clauses 15 to 18, wherein the oscillating motion system (110) includes an actuator (132) capable of having an oscillation speed (144) greater than a maximum value of a drill feed speed (126) of the drill feed motion system (106).

[0108] Clause 20. The method (700) of clause 19, wherein the actuator (132) is one of electromagnetic (138), mechanical (140), or hydraulic (142).

[0109] The description of different illustrative examples has been provided for the purpose of illustration and description and is not intended to be exhaustive or limited to the examples in the disclosed form. Many modifications and variations will be apparent to those skilled in the art. Further, different illustrative examples may provide different features compared to other illustrative examples. The selected one or more examples are selected and described in order to best explain the principles of the examples, their practical application, and to enable others skilled in the art to understand the disclosure of various examples with various modifications suitable for the intended specific use.

Claims

1. A vibration-assisted drilling system (102), comprising: A drill feed motion system (106) having a servo system (124) and a plurality of linear guides (120), the drill feed motion system (106) having a drill feed axis (108); an oscillatory motion system (110) having an oscillation axis (112), wherein the drill feed axis (108) is substantially parallel to and offset from the oscillation axis (112); a drill spindle (114) having a drill bit (116); and a mounting system (118) configured to connect the drill spindle (114) to the oscillating motion system (110), The oscillating motion system (110) includes a sliding surface (130), the sliding surface (130) includes a plurality of linear guides (134) and a plurality of bearing carts (136), the drill spindle (114) is mounted to the plurality of bearing carts (136), the oscillating motion system (110) further includes an actuator (132) having the oscillating axis (112), the actuator (132) being configured to move the plurality of bearing carts (136) along the plurality of linear guides (134) of the sliding surface (130), the sliding surface (130) being located between the servo system (124) and the drill spindle (114).

2. The vibration-assisted drilling system (102) of claim 1, further comprising: A controller (146) is configured to synchronize an oscillation speed (144) of the oscillatory motion system (110) and a rotational speed (148) of the drill bit (116) of the drill spindle (114).

3. The vibration-assisted drilling system (102) of claim 1, wherein the actuator (132) is one of electromagnetic (138), mechanical (140), or hydraulic (142).

4. The vibration-assisted drilling system (102) of claim 1, wherein the actuator (132) is capable of having an oscillation speed (144) greater than a maximum value of a drill feed speed (126) of the drill feed motion system (106).

5. The vibration-assisted drilling system (102) according to any one of claims 1 to 4, wherein the drill feed motion system (106) includes a plurality of bearing carts (128), wherein the oscillating motion system (110) is connected to the plurality of bearing carts (128).

6. A vibration-assisted drilling system (102), comprising: a drill feed motion system (106) having a servo system (124) and a plurality of linear guides (120), wherein the drill feed motion system (106) has a drill feed axis (108); an oscillatory motion system (110) having an actuator (132) and an oscillatory shaft (112), wherein the oscillatory shaft (112) is separate from the drill feed shaft (108); and a drill spindle (114) having a drill bit (116), said drill spindle (114) being mounted to said oscillating motion system (110), The oscillating motion system (110) includes a sliding surface (130), the sliding surface (130) includes a plurality of linear guides (134) and a plurality of bearing carts (136), the drill spindle (114) is mounted to the plurality of bearing carts (136), the oscillating motion system (110) further includes an actuator (132) having the oscillating axis (112), the actuator (132) being configured to move the plurality of bearing carts (136) along the plurality of linear guides (134) of the sliding surface (130), the sliding surface (130) being located between the servo system (124) and the drill spindle (114).

7. The vibration-assisted drilling system (102) of claim 6, wherein the actuator (132) is one of electromagnetic (138), mechanical (140), or hydraulic (142).

8. The vibration-assisted drilling system (102) of claim 6, further comprising: A controller (146) is configured to synchronize an oscillation speed (144) of the oscillatory motion system (110) and a rotational speed (148) of a drill bit (116) of the drill spindle (114).

9. The vibration-assisted drilling system (102) of any one of claims 6 to 8, wherein the actuator (132) is capable of having an oscillation speed (144) greater than a maximum value of a drill feed speed (126) of the drill feed motion system (106).

10. A method (700) of performing vibration-assisted drilling, comprising: A drill spindle (114) is moved toward the material (104) by a drill feed motion system (106) having a drill feed axis (108) and having a servo system (124) and a plurality of linear guides (120); rotating a drill bit (116) of the drill spindle (114) as the drill spindle (114) advances toward the material (104); and The drill spindle (114) is oscillated toward and away from the material (104) by an oscillating motion system (110), wherein the oscillating motion system (110) has an oscillation axis (112) that is substantially parallel to and offset from the drill feed axis (108), and wherein the oscillating motion system (110) connects the drill spindle (114) to the drill feed motion system (106), and wherein the oscillating motion system (110) includes a sliding surface (130) including a plurality of linear The oscillating motion system (110) further comprises a plurality of linear guides (134) and a plurality of bearing carts (136), the drill spindle (114) being mounted to the plurality of bearing carts (136), the oscillating motion system (110) further comprising an actuator (132) having the oscillating axis (112), the actuator (132) being configured to move the plurality of bearing carts (136) along the plurality of linear guides (134) of the sliding surface (130), the sliding surface (130) being located between the servo system (124) and the drill spindle (114).

11. The method (700) of claim 10, further comprising: An oscillation speed (144) of the oscillating motion system (110) and a rotational speed (148) of the drill bit (116) of the drill spindle (114) are synchronized using a controller (146) of a vibration-assisted drilling system (102) comprising the drill spindle (114), the oscillating motion system (110), and the drill feed motion system (106).

12. The method (700) of claim 11, wherein synchronizing the oscillation speed (144) and the rotational speed (148) of the drill bit (116) while oscillating the drill spindle (114) toward and away from the material (104) removes drilling debris (152) having a substantially uniform chip size (150).

13. The method (700) according to any one of claims 10 to 12, further comprising: connecting the oscillating motion system (110) to the drilling feed motion system (106); and The drill spindle (114) is mounted to the oscillating motion system (110).

14. The method (700) of any one of claims 10 to 12, wherein the actuator (132) is capable of an oscillation speed (144) that is greater than a maximum value of a drill feed speed (126) of the drill feed motion system (106).

15. The method (700) of claim 14, wherein the actuator (132) is one of electromagnetic (138), mechanical (140), or hydraulic (142).

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