Silent Drilling noise elimination technology using Microwave

Drilling holes is a fundamental operation in almost any industrial or constructionwork. Advanced drilling technologies are being developed for hard non-metallic materials (i.e. ceramics, concrete, marble, silicate, etc.). Mechanical drills satisfy most of the needs, but their operation causes loud n

Project Title

Silent Drilling noise elimination technology using Microwave

Project Area of Specialization

Artificial Intelligence

Project Summary

Drilling holes is a fundamental operation in almost any industrial or constructionwork. Advanced drilling technologies are being developed for hard non-metallic materials (i.e. ceramics, concrete, marble, silicate, etc.). Mechanical drills satisfy most of the needs, but their operation causes loud noise, vibrations, and dust effusion,and is not always effective. A drilling method that is based on the phenomenon of local hot spot generation by near-field microwave radiation. The microwave drill is implemented by a coaxial near-field radiator fed by a conventional microwave source. The near-field radiator induces the microwave energy into a small volume in the drilled material under its surface, and a hot spot evolves in a rapid thermal-runaway process. The center electrode of the coaxial radiator itself is then inserted into the softened material to form the hole. The method is applicable for drilling a variety of nonconductive materials. It does not require fast rotating parts, and its operation makes no dust or noise.

Project Objectives

The objective of this project is to integrate such technology which is beneficial for wide range of applications i.e from agriculture to construction of infrastructures. Microwave drilling uses the phenomena called 'hot-spot' which is undesired in most of the application and is produced by rapid nonuniform increase in local temperature due to thermal runaway effect.  The core principle of the microwave drill is to concentrate the generated microwave energy into a small spot, one that is much smaller than the microwave wavelength. This "focusing" effect is achieved by bringing a small monopole antenna into contact with the material to be drilled. The microwave energy tends to localize underneath the material’s surface in a thermal-runaway process. This generates a small hot spot where the material becomes softer or even molten. The near-field antenna is then inserted into the molten hot spot to form the contour of the hole (thereby allowing the hole to have non-circular shapes, depending, naturally, on the shape of the antenna). Depending on the application’s purposes, the antenna's pin is then either pulled out after having formed the drilled hole, or left inside to stick out as a nail. This direct pin insertion procedure was found feasible for diameters of 0.5 - 5 mm, and up to 3 cm in depth. For larger diameter holes, e.g., in the orderof 1 cm, or for deeper holes, the outer cylinder of the coaxial structure is made as a hollow reamer that is inserted into the hole and slowly rotated. In this manner, the device includes a mechanical means to remove any debris.

Project Implementation Method

The microwave energy localized underneath the material surface generates a small hotspot in which the material becomes soften or even molten. The concentrator pin itself is then inserted into the molten hot spot and shapes its boundaries. The hole can be shaped other than circular. Finally, the concentrator is pulled out from the drilled hole, and the material cools down in its new shape. The process does not require fast rotating parts, and it makes no dust and no noise. The microwave drill is effective for drilling and cutting in a variety of hard non-conductive dielectric materials, but not in metals. The latter reflect the radiation and therefor are almost not affected by the microwave drill. Hence, the microwave drill enables a distinction between different materials, and in particular between dielectrics and metals.

Specifically, the microwave drill can be implemented to make holes and grooves in dielectric coatings on metallic substrates (thermal barrier coating (TBC) for instance). Furthermore, it can expose existing holes in the metallic substrate coated by the ceramic, with no damage to the underlying metallic substrate.

The microwave drill can be implemented in relatively simple instruments, consuming moderate electrical powers. However, safety and RF interference considerations may limit its free public usage. Hence, the microwave drill concept is proposed first for embedded tooling in industrial manufacturing processes.

Benefits of the Project

The first advantage of microwave drilling is that they can be incorporated into a variety of instruments and tools. To date, these devices have demonstrated the capabilities to create holes in concrete, ceramic, glass, silicon, basalt, granite, and similar materials. Unlike mechanical drills, the microwave drill’s operation is quiet and clean. It does not use quickly rotating parts, nor does it cause mechanical friction or vibration, and it complies with safety standards. The second and unique advantage of microwave drilling is that their silent operation. This makes them ideally suited for use in construction work in sensitive areas where loud noise and vibration need to be avoided (e.g., residential and office areas, schools, hospitals, etc.)

The third advantage is that the microwave drill technology is able to use components found in domestic microwave ovens, thus it should be possible to provide low-cost tools for construction and maintenance work. Development of microwave drill technology will also be directed towards more specialized industrial applications (for instance, drilling, cutting, and jointing in the glass industry). The microwave drill technology may provide unique capabilities for advanced manufacturing processes.

Advanced features are being developed for more complicated drilling scenarios. These include sensing abilities to enable distinguishing between different materials in the drilled structure. The microwave drill will then also act as “radar” which will be able to “sense” the underlying material’s condition in a self-controlled process. The microwave-drill concept is further developed also for medical applications, and in particular for drilling in bone

Main effect

Mechanical contact

Mechanical motion

Radiation

Wavelength

Pollution

Diameter (typical)

Cost

Technical Details of Final Deliverable

By completing this project at the end we come up with the hardware product  which is capable of drilling any hard non-metallic materials (i.e. ceramics, concrete, marble, silicate, etc.)  with less noise as compared to regular drills, causing less noise pollution, which will be beneficial for health and well being of the human being.

Final Deliverable of the Project

HW/SW integrated system

Type of Industry

Medical , Agriculture , Manufacturing , Transportation , Others , Health

Technologies

Artificial Intelligence(AI)

Sustainable Development Goals

Good Health and Well-Being for People, Decent Work and Economic Growth, Industry, Innovation and Infrastructure

Required Resources

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