Segmented Orbital Drill for Composite Stack Machining
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Solution Overview
Problem
Machining composite stack materials results in accelerated wear of tool edges, leading to poor tool life even with advanced substrates and coatings.
Innovation Solution
A segmented orbital drill with a semi-finishing cutting portion and multiple finishing cutting portions, along with a clearance neck portion, is used to drill through layers of material, allowing for controlled wear and extended tool life by revealing fresh cutting edges and minimizing contact with the workpiece.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional drills are used to machine composite stack materials, then drilling function is achieved, but accelerated wear of tool edges occurs leading to poor tool life
Solution Approach 1:
The drill is divided into multiple segmented portions including a pilot portion and at least two cutting portions with different diameters. This segmentation allows each portion to perform specific functions: the pilot portion creates a guide hole while the cutting portions remove material, distributing wear across multiple edges and revealing fresh cutting edges as the drill progresses through the workpiece, thereby extending tool life
Solution Approach 2:
Different portions of the drill have different diameters and cutting edge configurations optimized for specific functions. The pilot portion has a smaller diameter for guide hole creation, while the cutting portions have larger diameters for material removal. This local differentiation ensures that wear occurs in a controlled manner that continuously exposes fresh cutting edges, addressing the accelerated wear problem
2Duration of action of moving object
If segmented orbital drill with multiple cutting portions is used, then tool life is extended by revealing fresh cutting edges, but device complexity increases
Solution Approach 1:
The drill features a segmented structure with a pilot portion and multiple cutting portions of different diameters. This segmentation, while increasing structural complexity, enables extended tool life by distributing wear across multiple cutting edges that are progressively exposed as the drill advances, allowing the tool to machine through composite stack materials for longer durations
Solution Approach 2:
The drill incorporates a clearance neck portion that creates dimensional variation along the drill's length, providing clearance between the drill body and the hole wall during orbital motion. This dimensional change allows the segmented portions to function effectively while managing the complexity through purposeful geometric variation
3Use of energy by moving object
If segmented orbital drill is used to reduce wear, then power consumption is reduced, but manufacturing precision requirements increase
Solution Approach 1:
The segmented structure with pilot and cutting portions of different diameters enables efficient material removal with reduced power consumption. The pilot portion creates a guide path while the cutting portions remove material in a controlled manner, maintaining hole quality precision while reducing energy requirements compared to conventional single-cutting-edge drills
Solution Approach 2:
The drill uses multiple cutting portions that engage the workpiece in sequence rather than all simultaneously, allowing partial action that reduces peak power consumption while maintaining manufacturing precision through the progressive engagement of cutting edges
Data Source
AI summary
A segmented orbital drill includes a segmented portion with a semi-finishing cutting portion and a plurality of finishing cutting portions. The semi-finishing cutting portion and finishing cutting portions are separated by grooves formed by a front wall and a rear wall. The segmented portion allows for a fresh cutting edge (i.e., rear wall of the groove) to be revealed as the orbital drill wears in the axial direction. The segmented portion also causes less contact with the workpiece, which reduces power consumption and minimizes deflection of the orbital drill. The segmented orbital drill also includes an optional pilot at one end of the drill, and a clearance neck portion between a shank and the segmented portion. A method of machining a workpiece using the segmented orbital drill is also disclosed.