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Benefit Assessment of High

Productivity Ultrasonic-Assisted
Drilling for Shipbuilding
April 25, 2013

Matt Short
Engineering Team Leader
Ultrasonics
614.688.5137
mshort@ewi.org

Harvey Castner
EWI
614-688-5063
hcastner@ewi.org

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, highfrequency acoustic energy to change


materials, processes.

Power supply
Ultrasonic
Transducer
60 ~

Ultrasonic energy
causes change in
Material or Process

Transmission

Material/Process

What is Ultrasonic Machining?




The application of ultrasonic vibrations to traditional


machining processes (drilling, turning, milling ) to improve
performance (e.g. faster drilling, drilling of hard materials,
better tool life, increased accuracy, )

Concepts of adding US
vibrations
to
various machining
processes

AcousTech Machining


Ultrasonic machining was investigated


with limited applications in the 1960s
and 1970s
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, and use conventional
metalworking tools to significantly reduce
operating costs while improving productivity

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

Portable Application Example




Integration of US power to portable


equipment for field repairs
Portable equipment
Drill diameter of 1.875-in.

Technology Demonstration

Results








Capable of performing operation in


36-sec. Not desirable due to
surface finish.
Successfully met surface
requirements at ~5-min operation
time.
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 2.3hrs per hole to 20-min per hole

Machine Tool Applications




Develop modular system to be fitted with new or existing


machine tools
System to work with industry standard spindle designs (CAT-,
HSK-, BT-, Morse Taper, etc.)
Design of system must isolate vibrates from spindle bearings,
machine structure, and machined part

Haas 5-axis MC

Machining Module Test Results

Static, Case Mounted

Critical measurement
is longitudinal displacement
at tool holder interface.

20.00
18.00
16.00
Long. Node Amp Displacement

14.00

Radial Amp at Nodal Position


Bore Face Amp Displacement

12.00

Tool Tip Displacement

Laser vibrometer data


proves that all vibrations
are isolated out of the
tool holder, therefore, spindle.

Back Mass Long. Amp Displacement

10.00

Radial Amp at Back Mass


Long. Amp. @ Tool Holder Interface

8.00

Rad. Amp. @ Back End of Case

6.00

Rad. Amp. @ Node Position w ith Case

4.00
2.00
0.00
0.00%

20.00%

40.00%

60.00%

80.00%

100.00%

120.00%

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.
Twenty-six potential ship-board drilling applications
were identified at one shipyard. 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.

Application Development


Portable drilling of steel selected as technology


demonstration
Portable magnetic drill similar to systems used by
shipyards.
Two new modules were designed, built, and tuned to
operate at 20 kHz. to allow for the demonstration of
a two-step drilling operation:
Module #1 will be fitted with a small diameter bit (e.g. a 7/8-in.
twist bit) and used to drill a new hole in the base material
Module #2 will be fitted with a larger diameter bit (e.g. a 1-1/2-in.
spade tip bit) and used to drill out the original hole.

Drilling feeds and speeds will be developed and the


improved capabilities of UD demonstrated.

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

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