Adaptive Material Removal for Variable Geometry Drill Bits
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Solution Overview
Problem
Conventional automated material removal systems are inefficient for custom manufactured articles like oilfield drill bits due to variations in geometry, making it impractical to program precise tool paths, which can result in removal of unwanted material while also risking the removal of wanted material.
Innovation Solution
An automated material removal system that uses a scanning device and controller to determine the geometry of the drill bit, calculate appropriate tool paths for a cutting tool, and remove unwanted material without affecting the desired geometry, employing a robot and cutting tool to precisely target and remove material between blades.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional automated material removal systems are used with custom manufactured articles, then automation is achieved, but manufacturing precision deteriorates due to geometry variations
Solution Approach 1:
The system dynamically adapts to geometry variations by using scanning devices to capture the actual article geometry and automatically adjusting tool paths in real-time, replacing static pre-programmed paths with dynamic adaptive control
Solution Approach 2:
The system changes operational parameters (tool paths, cutting speeds, feed rates) based on scanned geometry data, allowing the automated system to accommodate variations in custom manufactured articles while maintaining precision
2Manufacturing precision
If precise tool paths are programmed for automated material removal, then manufacturing precision is improved, but device complexity increases due to accounting for all variations
Solution Approach 1:
The scanning device performs preliminary measurement of the article geometry before material removal, capturing actual dimensions and variations to inform subsequent tool path generation
Solution Approach 2:
The system replaces complex mechanical programming and setup with automated scanning and computational algorithms that generate appropriate tool paths based on measured geometry, reducing device complexity
3Object-generated harmful factors
If material removal is performed on custom manufactured articles, then unwanted material is removed, but wanted material may be removed due to geometry variations
Solution Approach 1:
The system uses scanning feedback to continuously monitor article geometry and adjust tool paths accordingly, ensuring material removal only occurs where unwanted material is identified and preventing removal of wanted material
Solution Approach 2:
The system applies material removal selectively at specific locations identified as containing unwanted material, rather than uniform removal, preserving wanted material while eliminating harmful deposits
Data Source
AI summary
A method of removing unwanted material from an article having a variable form can include scanning the article and determining, based on the scanning, a location of the unwanted material, determining tool paths of a cutting tool which will result in removal of the unwanted material, and displacing the cutting tool along the tool paths, thereby removing the unwanted material. A material removal system for removing unwanted material from an oilfield drill bit can include a rotary indexing device which rotates the drill bit about a longitudinal axis of the drill bit, a scanning device which scans an outer surface of the drill bit, and a controller which determines a geometry of the drill bit, based on at least one scan by the scanning device, determines a location of the unwanted material, and determines tool paths of a cutting tool for removal of the unwanted material.