Vacuum Drilling System with Nested Coolant and Chip Extraction
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Solution Overview
Problem
Existing drilling systems fail to effectively contain and remove chips and coolant during metal drilling operations, leading to inefficiencies, health hazards, and reduced tool life, particularly in applications where portable machines are used and materials like titanium and aluminum are drilled.
Innovation Solution
A vacuum drilling system that integrates a through tool coolant supply with a central vacuum extraction system, featuring a cylindrical body with a cutting head, hollow shaft, and sealed coolant channels to efficiently extract chips and provide coolant, promoting precision and heat dissipation while maximizing tool life.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If solid twist drills with through coolant capability are used, then coolant can be delivered to the cutting zone, but chips and coolant are released into the environment without containment
Solution Approach 1:
The patent implements a hollow drill shaft with nested functional channels: an inner coolant channel delivers coolant to the cutting zone, while an outer vacuum channel surrounds it to capture and remove chips and coolant. This nested configuration allows both coolant delivery and chip containment within a single integrated tool structure, resolving the contradiction between effective cooling and environmental release.
Solution Approach 2:
The patent introduces a vacuum system as an intermediary mechanism between the drilling process and the environment. The vacuum channel acts as a mediator that captures chips and coolant at the source (drill exit) and transports them to a collection point, preventing direct release into the environment while maintaining effective coolant delivery to the cutting zone.
2Productivity
If vacuum is applied to remove chips, then chip extraction is improved, but the system is not suitable for metallic materials with different properties from CFRP
Solution Approach 1:
The patent designs a universal vacuum drilling system that can handle multiple material types (CFRP, aluminum, titanium, and other metals) by integrating adjustable parameters: variable vacuum pressure levels, adjustable coolant flow rates, and interchangeable drill bit configurations. This multi-functionality allows the same basic system architecture to adapt to different material properties and chip characteristics, resolving the limitation of material-specific design.
Solution Approach 2:
The patent employs parameter adjustment mechanisms to optimize performance across different materials: vacuum pressure can be increased for challenging materials like titanium, coolant flow rates can be modified based on material thermal conductivity, and drill geometry parameters can be changed to match material-specific cutting requirements. This parameter flexibility enables effective chip extraction across diverse material types.
3Ease of operation
If portable drilling machines are used, then drilling of large components at multiple locations is enabled, but no enclosure exists to isolate the drilling process
Solution Approach 1:
The patent extracts the chip containment and removal function from a fixed enclosed drilling system and integrates it directly into the portable drill tool itself. The vacuum channel and coolant channel are built into the drill shaft, allowing chip and coolant management to travel with the portable machine to any work location, eliminating the need for fixed enclosures while maintaining containment.
Solution Approach 2:
The portable drilling system performs its own chip containment and removal functions through integrated vacuum and coolant channels within the drill tool. The system is self-sufficient, carrying its own chip management capabilities to any location without requiring external enclosures or support infrastructure, thus maintaining portability while eliminating harmful releases.
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
The system effectively removes chips and coolant, enhancing drilling precision, reducing health hazards, and increasing tool life by utilizing vacuum pressure and coolant flow to maintain a clean drilling environment and prevent chip compaction.
Implementation Method 1
A vacuum source coupled to the hollow tube applies vacuum pressure through the plurality of openings and hollow shaft
Implementation Method 2
provide the coolant fluid to an area of the at least one cutting edge... to promote heat dissipation
Implementation Method 3
A coolant adapter provided on the body member provides a coolant fluid through at least one sealed channel in the body member exterior to the hollow shaft
Data Source
AI summary
A vacuum drilling system and methods is provided that may utilize both a through tool coolant supply as well as a central vacuum extraction system. The system may include a cutting head provided on a hollow tube and a vacuum source to apply vacuum pressure to the area of the cutting head via one or more chip inlets arranged proximate to the cutting head. Sealed coolant containment channels supply coolant to the area of the cutting head.