Offset-Axis Vibration Drilling for Mixed-Stack Hole Quality
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional drilling processes in mixed material stacks are time-consuming, generate excessive debris, and result in heat and friction, leading to poor hole quality and increased production times.
Innovation Solution
A vibration assisted drilling system with a drill feed motion system and an oscillation motion system, where the drill spindle is moved towards the material with a drill feed axis parallel to and offset from the oscillation axis, allowing independent control of drill feed and oscillation, thereby synchronizing oscillation speed and rotation speed to control chip size and reduce heat generation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional drilling is used to drill through mixed material stacks, then the drilling process can be performed, but it is time-consuming and limits production flow
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 assists in breaking the material bonds between different layers of the mixed material stack, significantly reducing drilling time and increasing production flow rate without compromising hole quality
2Productivity
If conventional drilling is used, then the drill bit can remove material, but it generates long coiled debris that becomes tangled around the drill bit
Solution Approach 1:
The vibration applied to the drill bit causes the cuttings to be broken into smaller, more manageable pieces rather than forming long coiled debris. The oscillating motion prevents the debris from wrapping around the drill bit, improving chip extraction efficiency and eliminating the harmful tangling effect
3Productivity
If conventional drilling is used, then the drill bit can penetrate the workpiece, but it creates friction and generates excessive heat
Solution Approach 1:
The mechanical vibration introduces an oscillating component to the drilling process that reduces continuous contact friction between the drill bit and workpiece. This vibration-assisted cutting action allows for faster drilling speeds while simultaneously reducing heat generation in the workpiece, resolving the contradiction between productivity and temperature control
4Productivity
If conventional drilling is used, then the drill bit can create holes, but it results in poor hole quality
Solution Approach 1:
The vibration assists in achieving cleaner cuts through the mixed material stack by reducing tool wear and minimizing heat-affected zones. This results in improved hole quality with better dimensional accuracy and surface finish, while maintaining high drilling efficiency
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 hole quality by ensuring reliable chip extraction, increasing production rates and reducing thrust and torque loads, thus improving surface roughness and drill bit fatigue life.
Implementation Method 1
The drill spindle is oscillated towards and away from the material by an oscillation motion system
Data Source
AI summary
A vibration assisted drilling system is presented. The vibration assisted drilling system comprises a drill feed motion system having a drill feed axis, an oscillation motion system having an oscillation axis, a drill spindle having a drill bit, and a mounting system configured to connect the drill spindle to the oscillation motion system. The drill feed axis is substantially parallel to and offset from the oscillation axis.