Methods of drill nozzle use and manufacture

In an embodiment, a drill nozzle includes a housing having a bristle brush ring attached. The housing of the drill nozzle may include an air intake, multiple coolant inlets, multiple coolant jets, a vacuum tube, and mounting flanges. The air intake may provide a thrust-vectored down draft into the vacuum tube. The coolant inlets may receive coolant fluid that may be expelled from the coolant jets towards a drill bit. Drilling debris and coolant fluid may be contained inside the bristle brush ring preventing damage and soiling of surrounding structures and areas and may be extracted with the vacuum tube. The drill nozzle may be attached to a drill motor unit of a numerically controlled drill jig, enabling the use of such numerically controlled drill jig for drilling high quality holes effectively into non-flat surfaces, for example, the leading edge extension spar of the F-18 aircraft.

BACKGROUND

An embodiment of the present invention generally relates to devices that can be attached to a drill motor and methods for providing coolant to a drill bit and for chip extraction during a drilling process and, more particularly, to a coolant feed drill nozzle with a thrust-vectored intake and a method for providing coolant to a drill bit and for vacuum extraction of drilling debris during drilling on non-flat surfaces.

Advanced aircraft, for example, the F-18, require many holes to be drilled into the fuselage of the aircraft. A numerically controlled drill jig exists for use on the forward fuselage of an F-18 aircraft. The numerically controlled drill jig offers an ergonomic, portable, foundation-free system for drilling holes into the skin of the aircraft that easily adapts to changes in the fabrication process while improving hole quality. This system utilizes a drill head unit that provides pressure to the fuselage skin of an aircraft, injects coolant towards a drill bit, and exhausts chips and dust occurring during the drilling process. Although the numerically controlled drill jig enables simple and low cost automation of the manufacturing process, the drill head unit of this system can only be used on the skins of the aircraft. Since the drill head unit of the numerically controlled drill jig is designed to apply pressure to the fuselage skins during the drilling process, a flat contact surface is necessary for the use of this drill head unit. Currently, if the numerically controlled drill jig is used for drilling holes into non-flat surfaces, for example, the leading edge extension spar of the F-18 aircraft that comprises recessed pockets and stiffened walls, the existing drill head unit must be removed. Since coolant injection and vacuum extraction of drilling debris is still needed, the machine operator must apply the coolant injection and vacuum extraction manually. However, manually applying the coolant to the drill bit and manually vacuum extracting the drilling debris is a dangerous, inconvenient, and time-consuming process.

There has, therefore, arisen a need to provide a drill head unit for use with the existing numerically controlled drill jig that enables the effective use of the numerically controlled drill jig on non-flat surfaces, for example, the leading edge extension spar of the F-18 aircraft. There has further arisen a need to provide a drill head unit that allows coolant injection towards the drill bit and vacuum extraction of the drilling debris such that the operation is safe, convenient, and timesaving. There has also arisen a need to provide a drill head unit, such as a drill nozzle, that may be easily attached to the existing numerically controlled drill jig and therefore, allows a low cost automation of the drilling process on non-flat surfaces during the manufacturing process of an aircraft. There has further arisen a need to provide a method for providing coolant to a drill bit during the drilling process on non-flat surfaces, for example the leading edge extension spar of the F-18 aircraft, while vacuum extracting the drilling debris, for example, chips, dust, and coolant, such that no drilling debris may damage the surrounding surfaces or may injure a machine operator.

Prior art further describes several drill motor vacuum attachments, for example U.S. Pat. Nos. 5,988,954 and 6,200,075 B1, both issued to Gaskin et al., and U.S. Pat. No. 5,033,917 issued to McGlasson et al. Even though these patents describe devices for vacuum extraction of drilling debris, for example, chip swarf and dust particles, these devices either don't allow coolant injection towards the drill bit (U.S. Pat. Nos. 5,988,954 and 6,200,075 B1) or these devices are too complex and not suitable to address the needs described above.

Prior art further discloses several devices for clamping a drill motor to a drill plate, for example, U.S. Pat. No. 5,395,187 issued to Slesinski et al., U.S. Pat. No. 5,482,411 issued to McGlasson, and U.S. Pat. No. 5,584,618 issued to Blankenship et al. These prior art devises comprise an apparatus for securely clamping a drill motor to a drill plate in order to drill precisely positioned holes in a work piece. These prior art devices comprise attachments to a drill motor but do not provide coolant injection towards a drill bit or vacuum extraction of the drilling debris during the drilling process. Further, these prior art devices are not suitable for the use on non-flat surfaces, for example, the leading edge extension spar of the F-18 aircraft, to address the needs described above.

As can be seen, there is a need for a drill nozzle that allows coolant injection towards a drill bit such that the drill bit may be engulfed during the drilling operation. Also, there is a need for a drill nozzle that allows vacuum extraction of drilling debris during the drilling operation, such that no chips, dust, or remaining coolant fluid may damage or soil the surrounding surfaces or may injure a machine operator. Further, there is a need for a drill nozzle that may be attached to the drill motor unit of a prior art numerically controlled drill jig to enable the use of the numerically controlled drill jig for non-flat surface of an advanced aircraft, for example, the leading edge extension spar of the F-18 aircraft. Moreover, there is a need for a method for providing coolant to a drill bit during the drilling process on non-flat surfaces, for example, the leading edge extension spar of the F-18 aircraft, while vacuum extracting the drilling debris, for example, chips, dust, and coolant, and, therefore, improving the drill hole quality.

SUMMARY

According to an embodiment of the inventive subject matter, a method includes providing a drill motor unit including a drill bit, and providing a drill nozzle. The drill nozzle may include a first section of a housing having a first open end and a second open end opposite from the first open end. The first open end and the second open end are terminal ends spaced apart along a first axis and define an internal chamber in the housing. The first section includes an air intake and a first coolant inlet. The drill nozzle also may include a second section of the housing intersecting the first section and extending downward from the first axis. The second section includes a vacuum tube in connection with the internal chamber of the first section. The drill nozzle also may include a bristle brush ring attached to the first section proximate to the first open end. The method also may include attaching the drill nozzle to the drill motor unit, and providing pressurized air to the air intake and creating a thrust-vectored down draft into the vacuum tube. The method also may include touching a surface to be drilled with the bristle brush ring, and providing coolant fluid through the first coolant inlet to expel the coolant fluid onto the drill bit. The method also may include drilling a hole into the surface and generating drilling debris, and vacuum extracting the drilling debris through the vacuum tube.

According to another embodiment of the inventive subject matter, a method for providing coolant to a drill bit and for vacuum extracting drilling debris generated during a drilling process on a surface includes providing a drill motor unit including a drill bit, and providing a drill nozzle. The drill nozzle includes a housing having an air intake, multiple coolant inlets, multiple coolant passageways, multiple coolant jets, a vacuum tube, and mounting flanges. The drill nozzle also includes a bristle brush ring attached to the housing. The method also includes attaching the drill nozzle to the drill motor unit using the mounting flanges, and providing pressurized air to the air intake and creating a thrust-vectored down draft into the vacuum tube. The method also includes providing coolant fluid through the coolant inlets and through the coolant passageways toward the coolant jets, and expelling coolant fluid onto the drill bit. The method also includes providing suction to the vacuum tube, drilling a hole into a non-flat surface and generating drilling debris, and vacuum extracting the drilling debris through the vacuum tube. The method also includes preventing drilling debris from exiting the housing of the drill nozzle towards the drill motor unit by providing the thrust-vectored down draft, containing the drilling debris and coolant fluid inside the bristle brush ring, wherein the bristle brush ring touches the surface, and preventing damaging and soiling surrounding structures and surfaces with the bristle brush ring.

According to another embodiment of the inventive subject matter, a method includes manufacturing a housing of the drill nozzle with a first section of the housing having a first open end and a second open end opposite from the first open end. The first open end and the second open end are terminal ends spaced apart along a first axis and define an internal chamber in the housing. The first section is manufactured with an air intake and a first coolant inlet. The housing also includes a second section of the housing intersecting the first section and extending downward from the first axis. The second section is manufactured with a vacuum tube being in connection with the internal chamber of the first section. The method also includes securing a bristle brush ring to the first section proximate to the first open end.

These and other features, aspects and advantages of embodiments of the present invention will become better understood with reference to the following drawings, description and claims.

DETAILED DESCRIPTION

The following detailed description is of the best currently contemplated modes of carrying out embodiments of the invention. The description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the embodiments of the invention, since the scope of the inventive subject matter is best defined by the appended claims.

Broadly, an embodiment of the present invention provides a drill nozzle suitable for drilling into non-flat surfaces. The drill nozzle according to an embodiment of the present invention may be attached to a drill motor unit, and therefore, eliminates the dangerous manual operation of the coolant and vacuum processes of the prior art. An embodiment of the present invention also provides a drill nozzle that allows coolant injection towards a drill bit during the drilling operation on non-flat surfaces while vacuum extracting the drilling debris at the same time such that no chips, dust, or remaining coolant fluid may exit the drill nozzle towards the drill motor unit, and such that surrounding surfaces and structures may not be spoiled or damaged. In contrast to the known prior art, the drill nozzle according to one embodiment of the present invention includes a housing having an air intake, coolant inlets, and a vacuum tube. The air intake provides an air curtain that prevents the drilling debris from exiting the drill nozzle towards the drill motor unit while the vacuum tube extracts the drilling debris and the coolant fluid provided by the coolant inlets away from the work area. Furthermore, the drill nozzle according to one embodiment of the present invention may have a bristle brush ring attached, which is not available in any known prior art drill motor attachment. The bristle brush ring prevents surrounding structures and surfaces from being soiled or damaged. In contrast to the prior art, these features of the drill nozzle according to one embodiment of the present invention facilitate using the drill nozzle for drilling into non-flat surfaces.

An embodiment of the present invention further provides a drill nozzle that is suitable for, but not limited to, being attached to a drill motor unit of a prior art numerically controlled drill jig, enabling the use of such numerically controlled drill jig for drilling high quality holes into non-flat surfaces, for example, the leading edge extension spar of an F-18 aircraft. In the prior art such a drill nozzle is not available. An embodiment of the present invention further provides a drill nozzle that has a simple mechanical design and may be manufactured using a fused deposition modeled process for rapid prototyping, which is relatively easily accessible and relatively inexpensive. An embodiment of the present invention still further provides a method for providing coolant to a drill bit during the drilling process on non-flat surfaces using a numerically controlled drill jig while vacuum extracting the drilling debris such that no drilling debris may damage or spoil the drill motor unit, to which a drill nozzle may be attached, or any surrounding structures. In contrast to the prior art, the provided drill nozzle as in one embodiment of the present invention includes a housing having an air intake, multiple coolant inlets, multiple coolant passageways, multiple coolant jets, a vacuum tube, and mounting flanges, and has a bristle brush ring attached. These features of the drill nozzle as in one embodiment of the present invention allow connecting the drill nozzle to a numerically controlled drill jig, providing an air curtain to avoid damage to the attached drill motor, providing coolant fluid onto a drill bit, providing suction for debris removal, and containing the drilling debris and coolant fluid inside the bristle brush ring, preventing damaging and soiling of surrounding surfaces and structures.

A drill nozzle according to one embodiment of the present invention will make it possible to use a prior art numerically controlled drill jig for drilling high quality holes into non-flat surfaces, for example, the leading edge extension spar of the F-18 aircraft. Therefore, no dangerous and ineffective manual operation of the coolant delivery and of the vacuum extraction process is needed as there is with the prior art use of a numerically controlled drill jig for drilling holes into the leading edge extension spar of the F-18 aircraft. Since the drill nozzle may be easily attached to a drill motor unit of the prior art numerically controlled drill jig after the existing drill head unit is removed, the drilling process on non-flat surfaces, for example, the leading edge extension spar of the F-18 aircraft, has now a reduced cycle time while providing accurately positioned high quality drill holes compared to prior art manual operation.

One embodiment of the present invention provides a drill nozzle that comprises a thrust-vectored intake that receives pressurized air and provides a thrust-vectored draft down into a vacuum tube. Therefore, an air curtain may be provided that prevents the rear escape of metal chips and composite dust that are generated during the drilling process, eliminating the potential of personal injury inherent to prior art manual operation. None of the known prior art devices provides an air curtain that prevents the rear escape of metal chips and composite dust. Furthermore, the drill motor unit to which the drill nozzle is attached may now be protected from being damaged by escaping metal chips or composite dust during the drilling process, which is not easily done during prior art manual operation.

One embodiment of the present invention provides a drill nozzle that may have a bristle brush containment ring attached that surrounds the drill bit and prevents metal chips, composite dust, and coolant fluid to spoil or damage surfaces or structures adjacent to the area of the drilling process. In the prior art, such a bristle brush containment ring is not available.

One embodiment of the present invention provides a drill nozzle that may be attached to a prior art numerically controlled drill jig using adjustable slides that make it possible to extend or retract the drill nozzle as needed due to the size of the drill bit used for a certain application. Therefore, the use of the drill nozzle is universal and not limited to a specific application, thus providing an advantage over prior art drill motor attachments. The drill nozzle according to one embodiment of the present invention may be used universally as an attachment to a variety of drill motor units providing coolant injection toward a drill bit and vacuum extraction of drilling debris during the drilling process on non-flat surfaces as well as flat surfaces. Consequently, the use of the drill nozzle according to one embodiment of the present invention is not limited to aircraft manufacturing but may be used for numerous industrial/commercial applications.

Referring now toFIGS. 1,2,3, and4, an external view of a drill nozzle10is illustrated according to one embodiment of the present invention. The drill nozzle10may include a housing11and a bristle brush ring12. The housing11may include a first section13and a second section15. The first section13may have a cylindrical elongated shape and a hollow interior and may extend along a first axis14. The second section15may have a cylindrical elongated shape and a hollow interior and may extend downward from the first section13along a second axis141in a preferably 90-degree angle in reference to the first axis14. The first section13intersects with the second section15of the housing11, as shown inFIG. 1. The first section13of the housing11may have a first open end16and a second open end17opposite from the first open end16. The first open end16and the second open end17may be terminal ends spaced apart along the first axis14. The first section13of the housing11may include an air intake18, and at least two coolant inlets19. The second section15of the housing11may include a vacuum tube21(as shown inFIGS. 5,6, and7) and at least two mounting flanges22. The second section15of the housing11may be located proximate to the second open end17of the first section13. The first open end16and the second open end17of the first section13of the housing11define a spherical internal chamber24therein that may be in connection with the vacuum tube21, as shown inFIGS. 3,5, and7. The air intake18has a preferably cylindrical shape and extends the housing11downward along the second axis141, preferably in a right angle to the first axis14. The air intake18may be located proximate to the second open end17and above the second section15of the housing11. The at least two coolant inlets19may have a cylindrical shape and extend the housing11sideward, preferably in a right angle to the first axis14. The air intake18may have a barbed fitting181for attaching a hose delivering pressurized air, as shown inFIG. 3. The hose delivering pressurized air may be secured to the air intake18using a band clamp or similar devices. Each of the at least two coolant inlets19may have a barbed fitting191for attaching a hose delivering coolant fluid, as shown inFIG. 3. A different hose delivering coolant may be attached to each coolant inlet19using a band clamp or similar device.

As shown inFIG. 3, the at least two mounting flanges22of the second section15of the housing11may be located proximate to the intersection of the first section13and the second section15and may extend sideward from the housing11to opposite sides, preferably in a right angle to the first axis14and the second axis141, as shown inFIGS. 1 and 3. Furthermore, each mounting flange22may include an aperture23for mounting the housing11to a drill motor unit30, as shown inFIG. 9. The second section15of the housing11may have an external vacuum source (not shown) attached, which may be secured with a band clamp or similar device.

The housing11of the drill nozzle10may be made of acrylonitrile butadiene styrene (ABS) plastic and may be manufactured in one piece using a fused deposition modeled process, a rapid prototyping technology. The bristle brush ring12may be attached to the first section13of the housing11by wrapping the bristle brush ring12around the housing11proximate to the first open end16(shown inFIG. 1) and may be secured using a band clamp or similar device (not shown). The bristle brush ring12is available for any outer diameter161of the first open end16. Furthermore, the bristle brush ring12used for the containment of metal chips, composite dust, and coolant fluid is commercially available.

Referring now toFIGS. 5,6,7, and8, an internal view of a drill nozzle10is illustrated according to one embodiment of the present invention. The first open end16may have a first outer diameter161and a smaller first inner diameter162. The second open end17may have a second outer diameter171and a smaller second inner diameter172(shown inFIG. 6). The first inner diameter162may be larger than the second inner diameter172. The second inner diameter172of the second open end17of the housing11may be designed to be large enough to allow a drill bit pass through and to move freely.

As illustrated inFIGS. 5,6, and7, each coolant inlet19includes an integrally molded coolant nozzle25for receiving coolant from an external source (not shown). Each coolant nozzle25may branch off into at least two coolant passageways26that may include coolant jets27at the opposite end. The coolant passageways26are integrally molded into the first section13of the housing11around the chamber24such that the coolant jets27are evenly spaced around the circumference of the first open end16and between the first outer diameter161and the first inner diameter162of the first end16. Further, the coolant jets27may be designed such that the expelled coolant fluid is directed towards the first axis14, as shown inFIG. 6. Such designed coolant jets27will enable that a drill bit passing through the first section13of the housing11along the first axis14may be engulfed with coolant fluid during the drilling operation.

A shown inFIGS. 5,6,7, and8, the air intake18may include a manifold air nozzle28that may be integrally molded into the air intake18during the manufacturing process of the housing11. The air nozzle28may be located at the back of the internal chamber24proximate to the second open end and above the vacuum tube21along the second axis141, as shown inFIGS. 5,6, and7. The air nozzle28may receive pressurized air from an external source (not shown) that may be attached to the air intake18. The air nozzle28may provide a thrust-vectored down draft29into the vacuum tube21, as shown inFIGS. 3 and 7. The thrust-vectored down draft29may function as an air curtain to prevent the rear escape of metal chips and composite dust that are generated during the drilling process through the second open end17of the housing11.

As illustrated inFIGS. 5 and 6, the internal chamber24may be in communication with the vacuum tube21, wherein the vacuum tube21may intersect with the internal chamber24proximate to the second open end17. This design may enable the removal of drilling debris generated during the drilling process as well as remaining coolant fluid through the vacuum suction. This process may be also supported by the thrust-vectored down draft29, as shown inFIGS. 3 and 7.

Referring now toFIGS. 9,10,11and12, a drill nozzle10attached to a drill motor unit30is illustrated according to another embodiment of the present invention. A mounting device40may include two horseshoe brackets31that may be attached to the base section of the drill motor unit30, as shown inFIGS. 9 and 10. The mounting device40may further include a mounting plate32in rigid connection with the horseshoe brackets31and two adjustable slides33. Each mounting flange22of the drill nozzle10may be connected with the mounting plate32using one of the adjustable slides33. A mounting screw34may be used to secure the adjustable slide33to the mounting flange22after insertion of the adjustable slide33through the aperture23in the mounting flange22. The mounting device40may be designed to position the drill nozzle10such that a drill bit35may pass through the internal chamber24of the housing11, such that it may extend coaxially with the first axis14, entering the chamber24from the second open end17of the housing11and exiting the chamber at the first open end16. Further, the drill nozzle10may be mounted to the drill motor unit30such that the air intake18is pointing downward and the vacuum tube21is pointing downward along the first axis14.

The distance of the drill nozzle10from the drill motor unit30may be adjusted according to the size of the drill bit by extending or retracting the adjustable slides33.FIG. 9shows the drill nozzle10in a retracted position whileFIG. 12shows the drill nozzle10in an extended position. A locking screw36may be used to hold the drill nozzle10in the desired position relative to the drill motor unit30, as illustrated inFIGS. 9,10, and12.

A method for providing coolant to a drill bit and for vacuum extracting drilling debris generated during the drilling process on non-flat surfaces may include the steps of: attaching a drill nozzle10to a drill motor unit30, adjusting the distance of the drill nozzle10from the drill motor unit30according to the desired size of the drill bit35by extending or retracting the adjustable slides33and securing the desired position with the locking screw36, providing coolant fluid through the coolant inlet19toward the coolant jets27, expelling coolant fluid towards the drill bit35, starting to drill a hole into a non-flat surface, vacuum extracting the drilling debris and remaining coolant fluid through the vacuum tube21, preventing metal chips and composite dust from exiting the drill nozzle10towards the drill motor unit30by providing pressurized air through the air intake18and by providing a thrust-vectored down draft29into the vacuum tube21using the manifold air nozzle28. Furthermore, by attaching the bristle brush ring12to the first section13of the housing11, metal chips, composite dust, and coolant fluid may be contained inside the bristle brush ring12preventing damage and soiling of surrounding structures and areas. The drill motor unit30, to which the drill nozzle may be attached, may be a drill motor unit of a prior art numerically controlled drill jig. The non-flat surface may be, for example, a leading edge extension spar of the F-18 aircraft.

Therefore, by using the coolant feed drill nozzle10with thrust-vectored intake, it may be possible to drill holes having a high quality and accuracy into non-flat surfaces while using the advantages of a numerically controlled drill jig. Although, the drill nozzle10as disclosed in one embodiment of the present invention may be most effective when attached to the drill motor unit30of a numerically controlled drill jig and for drilling holes, for example, into a leading edge extension spar of the F-18 aircraft, it may be used with other drill motor units and applications as well.