Rotary Plus Axial and Elliptical Vibration Ultrasonic Drill

The US Navy seeks an innovative process for fastening carbon fiber-reinforced polymers (CFRP) for military aircraft and target drones.  A single aircraft may have many fastener locations necessitating a robust, rapid fastening process. To address the critical need, X-wave Innovations, Inc. (XII) proposes to develop a rotary plus axial and elliptical vibration ultrasonic drill (RAE UD).  The proposed RAE UD leverages XII-developed ultrasonic technology and knowledge to create a CFRP drilling technique free from delamination and splintering.  The drilling technique utilizes elliptical vibration along with rotary ultrasonic machining (RUM), which have both been proven to improve machining performance, tool wear rate, and surface quality.  The key innovation of the proposed RAE UD technology is to utilize ultrasonic vibration in all three directions in addition to rotation of the diamond core drill to achieve a high-quality hole in CFRPs.  The proposed RAE UD does not require any coolant for the process and is therefore not at risk of contaminating the CFRP.  After the RAE UD creates a hole in the CFRP, any type of aircraft fastener, such as rivets, blind rivets, bolts, etc., can be used to fasten the pieces together.