Method and apparatus for limiting equipment burden when penetrating a mixed or composite material structure including metal utilizing a hammer-drill

Patent metadata

Field	Value
Publication number	US-10646985-B2
Application number	US-201615262756-A
Country	US
Kind code	B2
Filing date	Sep 12, 2016
Priority date	Sep 11, 2015
Publication date	May 12, 2020
Grant date	May 12, 2020

Abstract

A method employing an apparatus in conjunction with a hammer-drill to penetrate composite metal and non-metal structure or structures including, for example, thick metal or rebar encountered during concrete, rock or masonry boring operations without requiring a change in drill equipment.

First claim

The invention claimed is:

1. A method of drilling comprising:
identifying a task requiring rock drilling with a hammer-drill in a location where a likelihood exists of encountering a portion of metal and where it is desirable to carry only a single drill;
providing a metal-cutting bit comprising a cylindrical body formed with a first and second cylindrical sections, wherein the first section comprises a shank section, wherein the second section comprises a cutting section of a selected diameter to bore a desired diameter hole;
coupling a minimum of one protuberance to the first section at a first section coupling point a first distance from a longitudinal end of the first section opposite and facing away from the second section, wherein the first distance is selected so as to prevent full insertion of the first section into a chuck section of the hammer-drill, and wherein the first distance is further selected to prevent a hammer section in the hammer-drill from striking the longitudinal end of the first section while the hammer section of the hammer-drill is in operation;
providing said hammer-drill wherein the hammer-drill's hammer or percussive feature is continuously operating;
selecting a masonry bit with a diameter determined to create a desired bore in a rock;
securing the masonry bit in the hammer-drill and commencing rock drilling to establish a bore hole;
continuing drilling operations until the portion of metal is encountered;
removing the masonry bit and the hammer-drill from the bore hole and decoupling the masonry bit from the hammer-drill;
inserting the first section of the metal-cutting bit into the hammer drill chuck section until the protuberance comes into contact with the chuck section, then securing the metal-cutting bit in the hammer-drill and inserting the second section of the metal-cutting bit into the bore hole until contacting the portion of metal;
resuming drilling operations until the portion of metal is fully penetrated;
removing the metal-cutting bit and the hammer-drill from the bore hole and decoupling the metal-cutting bit from the hammer-drill; and
securing the masonry bit in the hammer-drill and inserting the masonry bit into the bore hole and continuing drilling operations until a selected depth of bore is achieved.

2. The method of claim 1 further comprising:
forming the second section as a cylindrical cutting section having a cylindrical side wall surrounding a longitudinal central axis of the metal-cutting bit passing between opposing ends of the metal-cutting bit, a circular cutting end opposite the first section and having a circumference when viewed from an axial direction thereof;
forming a guide tip with a plurality of cutting faces formed at an angle to the circular cutting end centered upon the longitudinal central axis, wherein the guide tip forms a cone with a base and an apex opposite each other, the base coupled to or extending from the circular cutting end; and
forming a plurality of helical flutes on the cylindrical side wall penetrating or extending into the second section, wherein the plurality of helical flutes are further formed in a section extending from the cutting end towards an interface area between the first and the second section, the cutting face further comprising cutting edges formed at an intersection or boundary of the helical flutes and the cutting face.

3. The method of claim 2 further comprising:
forming the protuberance during a manufacturing process as an integral portion of the first section.

4. The method of claim 2 further comprising:
forming the first section without the protuberance; and
providing the protuberance as a removable collar coupled to the shank section by a plurality of set screws.

5. The method of claim 2 further comprising:
forming the first section with an outer diameter of 18 mm;
milling a portion of the shank section opposite the cutting section with a plurality of open grooves and a plurality of locking segments for use in the chuck section of the hammer-drill, wherein the chuck section comprises a slotted drive system (SDS) Max chuck; and
forming the protuberance during a manufacturing process as an integral portion of the first section.

6. The method of claim 5 further comprising:
forming the apex of the guide tip to form a 135 degree angle between opposing sides of the guide tip; and
milling the helical flutes so as to create a 45 degree angle at the intersection or boundary of the helical flutes and the cutting face.

7. The method of claim 2 further comprising:
forming the first section with an outer diameter of 18 mm;
milling a portion of the shank opposite the cutting section with a plurality of open grooves and a plurality of locking segments for use in the chuck section of the hammer-drill, wherein the chuck section comprises a slotted drive system (SDS) Max chuck;
forming the first section without the protuberance; and
providing the protuberance as a removable collar coupled to the shank by a plurality of set screws.

8. The method of claim 7 further comprising:
forming the apex of the guide tip to form a 135 degree angle between opposing sides of the guide tip; and
milling the helical flutes so as to create a 45 degree angle at the intersection or boundary of the helical flutes and the cutting face.

9. The method of claim 1 further comprising:
forming a plurality of cutting edges circumferentially spaced around the cutting face of the metal-cutting bit configured to cut a plurality of chips from the portion of metal, wherein the plurality of flutes are configured to discharge the chips from the bore hole.

10. The method of claim 9 further comprising:
forming the protuberance during a manufacturing process as an integral portion of the first section.

11. The method of claim 9 further comprising:
forming the first section without the protuberance; and
providing the protuberance as a removable collar coupled to the shank by a plurality of set screws.

12. The method of claim 9 further comprising:
forming the first section with an outer diameter of 18 mm;
milling a portion of the shank opposite the cutting section with a plurality of open grooves and a plurality of locking segments for use in the chuck section of the hammer-drill, wherein the chuck section comprises a slotted drive system (SDS) Max chuck; and
forming the protuberance during a manufacturing process as an integral portion of the first section.

13. The method of claim 9 further comprising:
forming the first section with an outer diameter of 18 mm;
milling a portion of the shank opposite the cutting section with a plurality of open grooves and a plurality of locking segments for use in the chuck section of the hammer-drill, wherein the chuck section comprises a slotted drive system (SDS) Max chuck;
forming the first section without the protuberance; and
providing the protuberance as a removable collar coupled to the shank by a plurality of set screws.

Assignees

• Us Navy

Inventors

• Moan Brad
• Scheid Eric

Classifications

• B23B2228/36

  Multi-layered · CPC title

• B23B49/005

  Attached to the drill · CPC title

• B23B2226/75

  Stone, rock or concrete · CPC title

• B28D1/146 Primary

  Tools therefor (drill bits for earth or rock drilling E21B10/00) · CPC title

• B23B51/009

  Stepped drills · CPC title