Ultrasonic/sonic driller/corer

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The Ultrasonic/Sonic Driller/Corer (USDC) is a drilling device that uses vibrations in order to hammer its bit through materials, as opposed to traditional drilling methods. The drill uses a piezoelectric actuator as its source of power, and utilizes a variety of 'horns' to vibrate, or hammer, its bit through the material. [1] [2] A prototype of the drill was first released by NASA in April 2000, which weighed 1.5 lb. (.7 kg) and had the capacity to drill half-inch holes into granite using only 10 watts of power, [3] whereas the modern household half-inch drill requires 750 watts. [4] The USDC was originally designed to be able to drill through very rigid rock surfaces that would otherwise be damaged by a rotary drill, but has also shown potential usefulness to the field of medicine. It is the specific characteristics of the drill that make it ideal or practical for certain situations.

Drill tool for boring holes

A drill is a tool primarily used for making round holes or driving fasteners. It is fitted with a bit, either a drill or driver, depending on application, secured by a chuck. Some powered drills also include a hammer function.

NASA space-related agency of the United States government

The National Aeronautics and Space Administration is an independent agency of the United States Federal Government responsible for the civilian space program, as well as aeronautics and aerospace research.

Contents

How it works

The USDC is driven by a Piezoelectric stack actuator that creates the vibrations. The actuator vibrates at an extremely high frequency, making it ultrasonic, and it is these waves of vibration that are transmitted by the horn of the actuator all the way to the bit itself. The vibrations are created at the actuator and are transferred by the horn to a free mass. The free mass vibrates between the drill stem and the horn of the actuator to transmit the vibrations down the drill stem. The drill stem houses the drill bit, and the vibrations push the bit into the material. The repetitive impact on the drill stem by the free mass, creates stress pulses that transmit to the tip of the bit and into the rock. Ultimately, the repetitive strike of the bit produces enough strain on the surface to fracture it.

An actuator is a component of a machine that is responsible for moving and controlling a mechanism or system, for example by opening a valve. In simple terms, it is a "mover".

Ultrasound vibrations with frequencies above the human hearing range

Ultrasound is sound waves with frequencies higher than the upper audible limit of human hearing. Ultrasound is not different from "normal" (audible) sound in its physical properties, except that humans cannot hear it. This limit varies from person to person and is approximately 20 kilohertz in healthy young adults. Ultrasound devices operate with frequencies from 20 kHz up to several gigahertz.

Drill bit

Drill bits are cutting tools used to remove material to create holes, almost always of circular cross-section. Drill bits come in many sizes and shapes and can create different kinds of holes in many different materials. In order to create holes drill bits are usually attached to a drill, which powers them to cut through the workpiece, typically by rotation. The drill will grasp the upper end of a bit called the shank in the chuck.

Horn structures

There are four primary styles of horns, those being: [5]

History

NASA originally developed a prototype of the USDC in 2000, which weighed in at 1.5 pounds, or .7 kilograms. NASA has not discussed further development of the drill, but has mentioned that the drill could be downsized even further to fit in the palm of a hand. A second drill was developed to fit onto the Sojourner Rover, which had a drill head that weighed in at one pound alone, or .4 kilograms. [3]

Current Uses

The USDC was originally designed by NASA to bore through rock. The drill has been equipped on both of the Mars rovers to collect samples and take. However, plans to expand the USCD’s space uses include collecting samples from meteorites. The USDC is not limited to merely drilling and collecting samples, as the drill can be equipped side-by-side with sensors to take readings under the surface.

For preparing samples in TEM observation, such as silicon wafers, an USDC is used to cut specimens fitting the TEM holder (3 mm diameter). [6]

Transmission electron microscopy

Transmission electron microscopy is a microscopy technique in which a beam of electrons is transmitted through a specimen to form an image. The specimen is most often an ultrathin section less than 100 nm thick or a suspension on a grid. An image is formed from the interaction of the electrons with the sample as the beam is transmitted through the specimen. The image is then magnified and focused onto an imaging device, such as a fluorescent screen, a layer of photographic film, or a sensor such as a scintillator attached to a charge-coupled device.

Possible Uses

Use for the USDC has been foreseen in the medical field, for delicate surgeries or procedures involving the human skeletal structure. Operations involving the heart cannot involve high force, which could damage the organ or surrounding rib cage. The USDC’s low axial load ensures that little to no damage would be done to these fragile areas. The drill has also seen possibilities to excavate wire leads for pacemakers [3]

The human skeleton is the internal framework of the body. It is composed of around 270 bones at birth – this total decreases to around 206 bones by adulthood after some bones get fused together. The bone mass in the skeleton reaches maximum density around age 21. The human skeleton can be divided into the axial skeleton and the appendicular skeleton. The axial skeleton is formed by the vertebral column, the rib cage, the skull and other associated bones. The appendicular skeleton, which is attached to the axial skeleton, is formed by the shoulder girdle, the pelvic girdle and the bones of the upper and lower limbs.

Benefits

Low Power Usage

Overall, the USDC requires little power to operate. The USDC requires a very low axial load, or downward force applied, to be able to drill through tough surfaces such as granite, rock, or ice. Near zero torque is needed to operate the drill, as it does not bore using a traditional rotary force. [1] Comparatively, the USDC uses much less power to operate than other drill boring through hard surfaces.

Remoteness

Because of the low-axial load and negligible required torque, it is practical to use an ultrasonic drill for boring purposes where human operation cannot be present. The drill is able to properly function at both extremely low and high temperatures.

Drawbacks

Slurry Distribution

Due to the design of most ultrasonic drills, it is difficult to drill much past an inch into very dense material. This is because of the lack of slurry, or cutting fluid, to reach the drill bit in order to keep it clean and effective. Rotational drills do not experience this phenomenon as much due to the slotted cutting bit, which allows access of cutting fluid to the tip of the bit. [7] Ultrasonic drilling provides very little tolerance surrounding the bit, and so no such pathway is created.

Related Research Articles

Acoustics science that deals with the study of all mechanical waves in gases, liquids, and solids including vibration, sound, ultrasound and infrasound

Acoustics is the branch of physics that deals with the study of all mechanical waves in gases, liquids, and solids including topics such as vibration, sound, ultrasound and infrasound. A scientist who works in the field of acoustics is an acoustician while someone working in the field of acoustics technology may be called an acoustical engineer. The application of acoustics is present in almost all aspects of modern society with the most obvious being the audio and noise control industries.

Piezoelectricity the electric charge that accumulates in certain solid materials in response to applied mechanical stress

Piezoelectricity is the electric charge that accumulates in certain solid materials in response to applied mechanical stress. The word piezoelectricity means electricity resulting from pressure and latent heat. It is derived from the Greek word πιέζειν; piezein, which means to squeeze or press, and ἤλεκτρον ēlektron, which means amber, an ancient source of electric charge. French physicists Jacques and Pierre Curie discovered piezoelectricity in 1880.

A transducer is a device that converts energy from one form to another. Usually a transducer converts a signal in one form of energy to a signal in another.

A drill string on a drilling rig is a column, or string, of drill pipe that transmits drilling fluid and torque to the drill bit. The term is loosely applied to the assembled collection of the drill pipe, drill collars, tools and drill bit. The drill string is hollow so that drilling fluid can be pumped down through it and circulated back up the annulus.

Drilling cutting process that uses a drill bit to cut a hole of circular cross-section in solid materials

Drilling is a cutting process that uses a drill bit to cut a hole of circular cross-section in solid materials. The drill bit is usually a rotary cutting tool, often multi-point. The bit is pressed against the work-piece and rotated at rates from hundreds to thousands of revolutions per minute. This forces the cutting edge against the work-piece, cutting off chips (swarf) from the hole as it is drilled.

An electric toothbrush is a toothbrush that makes rapid automatic bristle motions, either back-and-forth oscillation or rotation-oscillation, in order to clean teeth. Motions at sonic speeds or below are made by a motor. In the case of ultrasonic toothbrushes, ultrasonic motions are produced by a piezoelectric crystal. A modern electric toothbrush is usually powered by a rechargeable battery charged through inductive charging when the brush sits in the charging base between uses.

Drilling rig

A drilling rig is a machine that creates holes in the earth's subsurface. Drilling rigs can be massive structures housing equipment used to drill water wells, oil wells, or natural gas extraction wells, or they can be small enough to be moved manually by one person and such are called augers. Drilling rigs can sample subsurface mineral deposits, test rock, soil and groundwater physical properties, and also can be used to install sub-surface fabrications, such as underground utilities, instrumentation, tunnels or wells. Drilling rigs can be mobile equipment mounted on trucks, tracks or trailers, or more permanent land or marine-based structures. The term "rig" therefore generally refers to the complex equipment that is used to penetrate the surface of the Earth's crust.

Piezoelectric motor

A piezoelectric motor or piezo motor is a type of electric motor based on the change in shape of a piezoelectric material when an electric field is applied. Piezoelectric motors use the converse piezoelectric effect of piezoelectric sensors, in which deformation or vibration of the piezoelectric material produces an electric charge. An electrical circuit makes acoustic or ultrasonic vibrations in the piezoelectric material, which produce linear or rotary motion. In one mechanism, the elongation in a single plane makes a series of stretches and position holds, analogous to the way a caterpillar moves.

Countersink type of conical-shaped cutter used to cut holes in materials

A Countersink is a conical hole cut into a manufactured object, or the cutter used to cut such a hole. A common use is to allow the head of a countersunk bolt, screw or rivet, when placed in the hole, to sit flush with or below the surface of the surrounding material. A countersink may also be used to remove the burr left from a drilling or tapping operation thereby improving the finish of the product and removing any hazardous sharp edges.

An ultrasonic motor is a type of electric motor powered by the ultrasonic vibration of a component, the stator, placed against another component, the rotor or slider depending on the scheme of operation. Ultrasonic motors differ from piezoelectric actuators in several ways, though both typically use some form of piezoelectric material, most often lead zirconate titanate and occasionally lithium niobate or other single-crystal materials. The most obvious difference is the use of resonance to amplify the vibration of the stator in contact with the rotor in ultrasonic motors. Ultrasonic motors also offer arbitrarily large rotation or sliding distances, while piezoelectric actuators are limited by the static strain that may be induced in the piezoelectric element.

Sonication application of ultrasound

Sonication is the act of applying sound energy to agitate particles in a sample, for various purposes such as the extraction of multiple compounds from plants, microalgae and seaweeds. The enhancement in the extraction of bioactive compounds achieved using sonication is attributed to cavitation in the solvent, a process that involves nucleation, growth, and collapse of bubbles in a liquid, driven by the passage of the ultrasonic waves. Ultrasonic frequencies (>20 kHz) are usually used, leading to the process also being known as ultrasonication or ultra-sonication.

Vibration isolation is the process of isolating an object, such as a piece of equipment, from the source of vibrations.

Shale shakers

Shale shakers are components of drilling equipment used in many industries, such as coal cleaning, mining, oil and gas drilling. They are the first phase of a solids control system on a drilling rig, and are used to remove large solids (cuttings) from the drilling fluid ("mud").

Directional boring steerable trenchless method of installing underground pipe, conduit, or cable in a shallow arc along a prescribed bore path by using a surface-launched drilling rig, with minimal impact on the surrounding area

Directional Boring, often undifferentiated from Horizontal Directional Drilling (HDD), is a minimal impact trenchless method of installing underground pipe, conduit, or cables in a relatively shallow arc or radius along a prescribed underground bore path by using a surface-launched drilling rig. With respect to the pipeline/utility industry, the term "Directional Boring" or "Bore" is generally reserved for mini/small sized drilling rigs, small diameter bores, and crossing lengths in terms of hundreds of feet. Generally, the term Horizontal Directional Drilling (HDD) is intended to describe large/maxi sized drilling rigs, large diameter bores, and crossing lengths in terms of thousand of feet. Although directional boring and HDD are similar in some respects to directional drilling associated with the oil industry, an equal comparison cannot be drawn between the procedures as they serve two entirely different functions. Directional Boring/HDD offers significant advantages over traditional cut and cover pipeline/utility installations and are routinely used when trenching or excavating is not practical. Directional Boring/HDD can be utilized with various pipe materials such as PVC, polyethylene, polypropylene, ductile iron, and steel as long as the pipe is sized appropriately to withstand installation stresses imparted during pullback.

Ultrasonic transducer

Ultrasonic transducers or ultrasonic sensors are a type of acoustic sensor divided into three broad categories: transmitters, receivers and transceivers. Transmitters convert electrical signals into ultrasound, receivers convert ultrasound into electrical signals, and transceivers can both transmit and receive ultrasound.

Ultrasonic machining

Ultrasonic machining, or strictly speaking the "Ultrasonic vibration machining", is a subtraction manufacturing process that removes material from the surface of a part through high frequency, low amplitude vibrations of a tool against the material surface in the presence of fine abrasive particles. The tool travels vertically or orthogonal to the surface of the part at amplitudes of 0.05 to 0.125 mm. The fine abrasive grains are mixed with water to form a slurry that is distributed across the part and the tip of the tool. Typical grain sizes of the abrasive material range from 100 to 1000, where smaller grains produce smoother surface finishes.

Sonotrode sonotrode

In ultrasonic machining, welding and mixing, a sonotrode is a tool that creates ultrasonic vibrations and applies this vibrational energy to a gas, liquid, solid or tissue.

Acoustic resonance spectroscopy (ARS) is a method of spectroscopy in the acoustic region, primarily the sonic and ultrasonic regions. ARS is typically much more rapid than HPLC and NIR. It is non destructive and requires no sample preparation as the sampling waveguide can simply be pushed into a sample powder/liquid or in contact with a solid sample. To date, the AR spectrometer has successfully differentiated and quantified sample analytes in various forms;. It has been used to measure and monitor the progression of chemical reactions, such as the setting and hardening of concrete from cement paste to solid. Acoustic spectrometry has also been used to measure the volume fraction of colloids in a dispersion medium, as well as for the investigation of physical properties of colloidal dispersions, such as aggregation and particle size distribution. Typically, these experiments are carried out with sinusoidal excitation signals and the experimental observation of signal attenuation. From a comparison of theoretical attenuation to experimental observation, the particle size distribution and aggregation phenomena are inferred.

Piezoelectric Bone Surgery is a process that utilizes piezoelectric vibrations in the application of cutting bone tissue. The process was developed by Tomaso Vercellotti and has been patented. It is indicated for use in oral, maxillofacial, cranial and spinal procedures.

References

  1. 1 2 JPL's NDEAA Ultrasonic/Sonic Driller/Corer (USDC) Homepage, Dr. Yoseph Bar-Cohen, JPL
  2. Modeling and Computer Simulation of Ultrasonic/Sonic Driller/Corer (USDC), IEEE Transactions of Ultrasonics, Sonics and Frequency Control Vol. 50, No. 9, (2003), pp. 1147-1160.
  3. 1 2 3 NASA DEVELOPS A DRILL FOR THE FUTURE, MEDIA RELATIONS OFFICE/JET PROPULSION LABORATORY
  4. Average Power Consumption of Household Appliances, ABS Alaskan, Inc.
  5. The Development of Ultrasonic Drilling Device, Department of Automation and Applied Informatics, Budapest University of Technology and Economics
  6. Paul E. Fischione, Thomas F. Kelly, Amber M. Dalley, Louis M. Holzman and David Dawson-Elli (1991). Advances in Ultrasonic Disk Cutting and Precision Dimpling. MRS Proceedings, 254, 79 doi:10.1557/PROC-254-79.
  7. Ultrasonic Drilling Apparatus Patent, Edward L. Duran