Ultrasonic Needle Array for Composite Perforation
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Solution Overview
Problem
Conventional methods for forming acoustic liners with perforations, such as drilling, are time- and capital-intensive, expensive, and difficult when dealing with composite materials, especially due to the need for frequent drill bit replacement and the limitations of traditional ultrasonic drilling which requires rotation and cooling fluids.
Innovation Solution
A needle array configured to form ultrasonic perforations without rotating the needles or using a slurry, where the needles are arranged to extend from a support plate and vibrated at an ultrasonic frequency to create multiple holes simultaneously in a composite material, using additive manufacturing for the needles and support plate, and optionally incorporating a remote heating unit for localized heating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional drilling methods are used to form perforations, then holes can be formed in the workpiece, but the process is time- and capital-intensive with frequent drill bit replacement
Solution Approach 1:
The invention divides the drilling operation into multiple simultaneous operations by using an array of multiple drill bits arranged in a specific pattern. Instead of drilling holes sequentially with a single bit, multiple bits drill simultaneously, dramatically reducing the total time required to create perforations in the workpiece.
Solution Approach 2:
The invention combines multiple drilling operations into a single integrated tool assembly. The array of drill bits is mounted together on a single tool holder, allowing all bits to be driven simultaneously by one motor, consolidating what would otherwise require multiple separate drilling operations into one unified process.
2Productivity
If multiple holes are drilled at once using conventional methods, then productivity increases, but tooling costs increase due to wear on drill bits
Solution Approach 1:
The invention uses relatively inexpensive drill bits arranged in an array that can be easily replaced as a group when wear occurs. Rather than investing in expensive, highly durable individual bits, the system uses multiple simpler bits that are replaced collectively, reducing the cost per hole drilled while maintaining high productivity.
3Productivity
If traditional ultrasonic drilling is used, then drilling speed improves, but rotation and cooling fluids are required which complicates the process
Solution Approach 1:
The invention uses ultrasonic vibration of the drill bit array at high frequency to facilitate material removal without requiring rotational motion. The vibrational motion allows the bits to effectively drill through materials while eliminating the need for complex rotation mechanisms and cooling fluid systems, simplifying the overall drilling process.
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 method reduces the time and cost of forming perforations, minimizes tool wear, and improves material properties by allowing for efficient formation of multiple holes without the need for cooling fluids, enhancing the manufacturing process for acoustic liners.
Implementation Method 1
each respective needle of the plurality of needles is configured to form a respective hole in the workpiece when the needle array is vibrated along the longitudinal axis at an ultrasonic operating frequency
Implementation Method 2
Ultrasonic drilling is a technique that uses high frequency, low amplitude vibrations of a tool, or bit, against a workpiece surface to remove material from the workpiece by micro-chipping or erosion with abrasive particles
Data Source
AI summary
Needle arrays for forming ultrasonic perforations may be formed from additive manufacturing and with non-circular cross-sectional areas for forming a plurality of holes, or perforations, in a thin sheet material. Methods of forming a plurality of perforations in a thin sheet of a composite material may include positioning the thin sheet under the needle array, repeatedly contacting the surface of the thin sheet to form perforations therein, translating the thin sheet and/or the needle array such that a different area of the thin sheet is positioned under the needle array, and again repeatedly contacting the surface of the thin sheet to form the perforations therein. Related systems may include an ultrasonic actuator, a needle array, and a remote heating unit configured to heat the workpiece while the perforations are formed therein.