The long and sharp chip created during drilling operations has always been an issue for productivity and quality.
Vibration Assisted Drilling adds an oscillating motion in the tool feed direction which cuts the chips into small pieces which prevents chip build-up and clogging of the chip evacuation system.
An additional benefit is the reduced temperature of the drilling process which is due to the cutting tools intermittant contact with the material during Vibration Assisted Drilling.
As a result, Vibration Assisted Drilling can greatly increase both hole quality and productivity, especially in difficult-to-drill composite/metal stacks prevalently used in the aerospace sector.
Vibration Assisted Drilling has previously been integrated in portable drilling tools but has yet to find widespread use in automated production systems.
To supply the market with a solution, VibiCore has developed a new drill spindle that shows very satisfactory test results and has the potential to satisfy a great market demand.
The drilling device can infeed much faster than existing products
The drill equipment is autonomous, the drilling process follows a predefined recipe
All process parameters, feeds, amplitude, frequencies and spindle speed can be changed in real time independent of each other, thus making it possible to use the optimal cutting data for the layer of material which is currently being processed
No limitations for the combination of vibration frequencies and amplitude
Process monitoring with thresholds for warnings and alarms secures the hole quality
Possibilities to adapt the process in real time to handle inconsistencies in the material and tool wear due to high-speed logging capabilities (0.1 ms resolution)
Almost all reaction forces from the vibration drilling are cancelled out. (makes it possible to drill aircraft structures with a standard robot)
The drill equipment can be designed as a manual tool, in a CNC-machine or integrated in a robot
The concept is scalable (the prototype is developed for up to Ø15mm, but Ø30mm is possible with the same concept)
The vibration movement is not sinusoidal but is instead a peak with very short rise and fall time. (larger material removal per revolution and sharper break-neck on the chip)
When drilling in stacked material, it is important to have different process parameters for each layer. The VibiCore’s solution provides the possibility to optimize the process parameters in any desired position.
The mechatronic device can cancel out the reaction forces created by the high accelerations in the vibration peak.
This means that a weaker structure as an industrial robot arm will only hold against the true cutting force.
The remaining cutting force are easier to measure and can be used for sensing layers and commanding the robot force control if needed.
Oscillation curve of a typical vibration drilling so far in the market.
Oscillation curve of a typical vibration drilling with the Vibicore prototype.
In the figure, it is possible to see the vibration movement overlaying the feeding movement of the drill.
This vibration-pattern is totally different from what has been used in the market so far see fig.1.
Difference in time of full cutting, VibiCore vs Competitors.
The material removal rate is significant larger per cut.
The energy needed to produce this peak is not practically achievable with electronic devices as piezo elements or magnetic bearing solutions..
The application interface runs on an Omron controller
Easy and fast programming and process control with possibilities to store programs.
When the program is downloaded to the controller the drilling can be performed without the HMI.
The software can record the complete drilling process and present data curves measured in real time with high time resolution.
The application interface runs on an Omron controller
Easy and fast programming and process control with possibilities to store programs.
When the program is downloaded to the controller the drilling can be performed without the HMI.
The software can record the complete drilling process and present data curves measured in real time with high time resolution.
The automatically generated program shows all relevant process data in a list defined per step.
It can be manually edited and stored in the process tuning.
The program data downloads in the background to the controller after changing any field.
The program can be stored in the controller, or any computer connected in the network as backup.
This shows a recording session from a drilling impact. Time and amplitude are displayed.
Each square shows a point recorded.
Data can be exported as common file formats for further analyze.
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