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Benefit Assessment of High

Productivity Ultrasonic-Assisted
Drilling for Shipbuilding
April 25, 2013

Matt Short
Engineering Team Leader

Harvey Castner

Outline      Background and Advantages of Ultrasonic Machining Project Objectives and Approach Shipyard Survey Applications Development Future Work .

UM – Part of Field of High Power Ultrasonics (HPU) • HPU … application of intense. processes. Power supply Ultrasonic Transducer 60 ~ Ultrasonic energy causes change in Material or Process Transmission Material/Process . highfrequency acoustic energy to change materials.

faster drilling. drilling of hard materials. milling …) to improve performance (e. turning. increased accuracy.g. better tool life.What is Ultrasonic Machining?  The application of ultrasonic vibrations to “traditional” machining processes (drilling. …) Concepts of adding US vibrations to various machining processes .

and use conventional metalworking tools to significantly reduce operating costs while improving productivity .AcousTech Machining   Ultrasonic machining was investigated with limited applications in the 1960’s and 1970’s Prior work relied on heavily modified systems using one off tooling ─ Specialty machines requires additional capital investment ─ Unique tooling increases operation costs and training requirements  AcousTechTM Vision ─ Develop modular device that can be attached to existing machine tools.

Technology Overview  AcousTechTM Machining ─ Application of intense acoustical vibrations to conventional cutting tools ─ HP Transducer ─ 5kW total power ─ 20kHz frequency ─ Adjustable displacement ─ Longitudinal wave  Benefits ─ ─ ─ ─ ─ Reduced forces/torque Lower tool temperatures Increased feeds Improved chip evacuation Improved surface finish Video of Drill Bit Excitation .

875-in. .Portable Application Example  Integration of US power to portable equipment for field repairs ─ Portable equipment ─ Drill diameter of 1.

Technology Demonstration .

3hrs per hole to 20-min per hole . Successfully met surface requirements at ~5-min operation time.Results        Capable of performing operation in 36-sec. Improved true position of hole Maintained ability to revert to Morse taper tooling Completely isolated vibrations from drill head Capable of performing several operations with same drill bit Reduced total cycle time from 2. Not desirable due to surface finish.

Morse Taper. and machined part Haas 5-axis MC . machine structure. BT-. HSK-.) Design of system must isolate vibrates from spindle bearings. etc.Machine Tool Applications    Develop modular system to be fitted with new or existing machine tools System to work with industry standard spindle designs (CAT-.

00% 120.00 Radial Amp at Nodal Position Bore Face Amp Displacement 12. Amp Displacement 10.00 2.00% 80.00 16. Amp. Back Mass Long.00 Radial Amp at Back Mass Long. @ Back End of Case 6. spindle. Amp.Machining Module Test Results Static.00% 20. @ Node Position w ith Case 4.00 0. 20.00 18.00 0.00 Rad.00% . Node Amp Displacement 14. Case Mounted Critical measurement is longitudinal displacement at tool holder interface.00% 40.00 Long. Amp.00% 60. @ Tool Holder Interface 8.00 Tool Tip Displacement Laser vibrometer data proves that all vibrations are isolated out of the tool holder.00 Rad.00% 100. therefore.

Project Summary Objective: This project will assess the potential of shipbuilding applications that can benefit from the use of ultrasonic assisted drilling to shorten build time and reduce the cost of ship construction. Scope of Work:  Task 1 Shipyard Survey  Task 2 Application Development  Task 3 Business Case Analysis and Reporting  Task 4 Industry Workshop .

Shipyard Survey   EWI identified high-volume or high-cost drilling applications that can benefit from improved drilling methods at the participating shipyards. Data gathered included: ─ ─ ─ ─  Current drilling practices Type of drilling tools and machines Material types and thicknesses Sizes and number of holes drilled Selected applications for development and demonstration. Twenty-six potential ship-board drilling applications were identified at one shipyard. .

a 7/8-in. and tuned to operate at 20 kHz.Application Development    Portable drilling of steel selected as technology demonstration Portable magnetic drill similar to systems used by shipyards. twist bit) and used to drill a new hole in the base material ─ Module #2 will be fitted with a larger diameter bit (e. Two new modules were designed. built.g. .g.  Drilling feeds and speeds will be developed and the improved capabilities of UD demonstrated. a 1-1/2-in. spade tip bit) and used to drill out the original hole. to allow for the demonstration of a two-step drilling operation: ─ Module #1 will be fitted with a small diameter bit (e.

Shipyard Applications  First prototype fabricated around design of Morse Taper attachment method ─ Confirmed isolation of vibrations ─ Utilized external slip ring assembly for power transmission ─ Performed drilling studies to measure level of impact ─ Integrated various tool attachment methods  Next steps: ─ Complete business case analysis of shipyard applications ─ Hold workshop to demonstrate technology ─ Compete final report .

Questions .