Offset-Axis Vibration Drilling for Reliable Chip Extraction
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Solution Overview
Problem
Conventional drilling processes in mixed material stacks are time-consuming, generate excessive debris, and result in heat and friction, leading to inefficient production and unreliable chip extraction.
Innovation Solution
A vibration assisted drilling system with a drill feed motion system and an oscillation motion system, where the drill spindle is moved along a drill feed axis parallel to and offset from the oscillation axis, allowing independent control of drill feed and oscillation, synchronized with the drill bit's rotation speed to control chip size and reduce heat.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional drilling is used to drill through mixed material stacks, then the drilling process is simple and straightforward, but the production time increases and production rate decreases
Solution Approach 1:
The patent applies mechanical vibration to the drill bit through a vibration generator, causing the drill bit to oscillate during the drilling process. This vibration reduces material strength and facilitates easier cutting, thereby decreasing drilling time and increasing production rate when drilling through mixed material stacks.
Solution Approach 2:
The drill bit performs periodic oscillating motion in addition to rotation, creating intermittent cutting action. This periodic vibration allows the drill bit to periodically break through material resistance, reducing overall drilling time and improving production efficiency.
2Reliability
If conventional drilling is used, then the drilling process is straightforward, but debris becomes tangled around the drill bit and chip extraction becomes unreliable
Solution Approach 1:
The vibration generator induces oscillating motion in the drill bit, which prevents debris from becoming tangled around the drill bit. The vibrational movement continuously loosens and breaks up chips, ensuring reliable chip extraction without requiring additional complex extraction mechanisms.
3Temperature
If conventional drilling is used, then the drilling process is simple, but friction generates excessive heat in the workpiece
Solution Approach 1:
The mechanical vibration reduces the contact time between the drill bit and workpiece material, decreasing friction-generated heat. The oscillating motion creates periodic separation that allows heat dissipation, thereby reducing workpiece temperature without requiring additional cooling systems.
4Force
If conventional drilling is used, then the drilling process is straightforward, but thrust and torque loads are excessive
Solution Approach 1:
The vibration generator creates oscillating motion that reduces material strength during drilling, thereby decreasing the thrust and torque loads required. The periodic vibration facilitates easier material removal, reducing the force needed to advance the drill bit through mixed material stacks.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces debris size, minimizes heat generation, and enhances production efficiency by ensuring reliable chip extraction and improved hole quality, increasing production rates and reducing thrust and torque loads.
Implementation Method 1
The drill spindle is oscillated towards and away from the material by an oscillation motion system
Data Source
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AI summary
A vibration assisted drilling system (102) is presented. The vibration assisted drilling system (102) comprises a drill feed motion system (106) having a drill feed axis (108), an oscillation motion system (110) having an 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 oscillation motion system (110). The drill feed axis (108) is substantially parallel to and offset from the oscillation axis (112).