MULTI-JET NOZZLE

Abstract

Some embodiments can be implemented as a system, method, or nozzle and can include some of these features. A fluid jet cutting system can include a frame, a cutting head, a high-pressure fluid source, an abrasive source, and an actuator. The cutting head can include a fluid inlet, an orifice, a mixing chamber, and a fluid jet nozzle. The fluid jet nozzle can include an elongated body which can include a body axis, a fluid inlet orifice that can be in fluid communication with a plurality of conduits, and a source of high speed fluid and abrasive, which can be the cutting head's mixing chamber. Each of the plurality of conduits can: be in fluid communication with the fluid inlet orifice; have its own conduit axis that forms an angle with the body axis; and be in fluid communication with its own fluid outlet orifice.

Description

RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application Ser. No. 61/480,498 which is entitled “Drilling Multiple Holes Simultaneously Via Waterjet”, filed Apr. 29, 2011, the contents of which are hereby incorporated by reference.

FIELD

This disclosure generally relates to high pressure fluid jet cutting. In particular, an apparatus, system and method for simultaneously drilling a plurality of holes are disclosed.

BACKGROUND

Fluid jet cutting systems utilize high velocity fluid to cut materials. Some fluid jet cutting systems use abrasives mixed with the fluid to provide enhanced cutting capability. Fluid jet cutting systems can provide clean, and substantially burr-free cuts in a wide variety of materials including, for example, leather, plastics, metals (e.g. aluminums and steels), and glass.

Fluid jet cutting systems can be utilized to generate cuts of a wide variety of shapes. In order to make these cuts, many fluid jet cutting systems are connected to a motion system. In many cases, motion systems and fluid jet systems can be large and expensive, rendering system up-time a critical factor in the economics of utilizing such cutting systems.

Many fabrication processes require the cutting of a plurality of identical, uniformly spaced features within or from a work piece, which can include drilling a plurality of holes.

SUMMARY

Embodiments of the invention include a high pressure fluid jet cutting system. In some embodiments, the fluid jet cutting system can include a frame, a fluid jet cutting head coupled to the frame, a high-pressure fluid source including a pressurized fluid supply line, an abrasive source including an abrasive source supply line, and an actuator coupled to the frame. In some embodiments, the fluid jet cutting head can include a fluid inlet, an orifice in fluid communication with the fluid inlet, a mixing chamber in fluid communication with the orifice, and a fluid jet nozzle in fluid communication with the mixing chamber.

In some embodiments, the fluid jet cutting system can include a high-pressure fluid source, an abrasive source, and an actuator. The high-pressure fluid source can include a pressurized fluid supply line which can be connected to the fluid jet cutting head's fluid inlet and can be configured to supply pressurized fluid to the fluid jet cutting head's fluid inlet. The abrasive source can include an abrasive source supply line which can be connected to the fluid jet cutting head's mixing chamber and can be configured to supply abrasive to the fluid jet cutting head's mixing chamber. The actuator can be coupled to the frame and it can be configured to control the flow of pressurized fluid from the high-pressure fluid source to the fluid jet cutting head's fluid inlet.

Embodiments of the invention include a fluid jet nozzle that can include an elongated body. In some embodiments, the elongated body can include a body axis, a fluid inlet orifice that can be in fluid communication with a source of high speed fluid and abrasive, and a plurality of conduits. Each of the plurality of conduits can: be in fluid communication with the fluid inlet orifice; have its own conduit axis that forms an angle with the body axis; and be in fluid communication with its own fluid outlet orifice. In some embodiments, a source of high speed fluid and abrasive can be the cutting head's mixing chamber.

Embodiments of the invention include a method of drilling a plurality of holes into a work piece. In some embodiments, the method can include installing a work piece in a fluid jet cutting system and activating an actuator of the fluid jet cutting system. Activating the actuator can dispense high speed fluid and abrasive from the fluid outlet orifices of the fluid jet cutting head's nozzle which can simultaneously drill a plurality of holes into the work piece.

Embodiments of the invention can include one or more of the following features. For example, the elongated body of the fluid jet nozzle can be made of carbide. A portion of the elongated body of the fluid jet nozzle can have a rectangular cross sectional shape. The fluid jet nozzle can have a cutting head connector which can be adapted to attach the nozzle's elongated body to a fluid jet cutting head.

Embodiments of the invention can include one or more of the following features. For example, an angle formed by a conduit axis and the body axis may be substantially zero degrees. An angle formed by a conduit axis and the body axis may be greater than an angle formed by another conduit axis and the body axis. An angle formed by a conduit axis and the body axis may be approximately two degrees.

Embodiments of the invention can also include one or more of the following features. In some embodiments, the plurality of conduits can all have the same cross sectional shape (e.g., circular, elliptical, diamond, rectangular, triangular, etc.). In some embodiments, the plurality of conduits within a nozzle can include a mixture of cross sectional shapes. For example, two conduits can have a circular cross sectional shape, and two conduits can have a diamond cross sectional shape. Other combinations of cross sectional shaped conduits within a nozzle are also possible. The diameter of conduits with a circular cross sectional shape can be between approximately 0.01 inches and approximately 0.06 inches. Some embodiments include conduits with circular cross sectional shapes that have different diameters (e.g., one or more of the conduits have a diameter of 0.02 inches, and one or more of the conduits have a diameter of 0.05 inches). The cross sectional shape of a conduit can be determined by the shape requirements of a finished work piece, so that, for example, if a rectangularly shaped hole was required, a nozzle can have a conduit with a rectangular cross sectional shape.

Embodiments of the invention can also include one or more of the following features. For example, the fluid jet nozzle can also have an outlet face that can be substantially normal to the body axis, and the fluid outlet orifices can be disposed on the outlet face. The fluid outlet orifices can be positioned on the outlet face such that each of the fluid outlet orifices can be symmetrically placed about the center of the outlet face. The fluid outlet orifices can be positioned on the outlet face such that each of the fluid outlet orifices substantially locates one of the six vertices of a hexagon. The fluid outlet orifices can be positioned on the outlet face such that each of the fluid outlet orifices can be asymmetrically placed about the center of the outlet face. The fluid outlet orifices can be positioned on the outlet face such that each of the fluid outlet orifices substantially locates vertices and endpoints of a “W”. The positioning of the fluid outlet orifices on the outlet face can also be determined by the shape requirements of a finished work piece, so that, for example, if a star-shaped hole pattern was required, the fluid outlet orifices can be positioned on the outlet face in a star-shaped pattern. The fluid outlet orifices can each be configured to provide a fluid jet cutting stream.

Embodiments of the invention can also include one or more of the following features. In some embodiments, the high-pressure fluid source may be configured to supply, and the fluid jet cutting head's fluid inlet and orifice may be adapted to withstand, fluid that is pressurized to substantially between 50,000 and 100,000 pounds per square inch (psi), which corresponds to the fluid pressures currently in use to drill a metal. Fluid pressures in excess of 100,000 psi are also contemplated as technology advances make such fluid pressures available to fluid jet cutting systems. In some embodiments, the high-pressure fluid source may be configured to supply, and the fluid jet cutting head's fluid inlet and orifice may be adapted to withstand, fluid that is pressurized to substantially between 10,000 and 50,000 psi, which corresponds to the fluid pressures currently in use to drill composites, including carbon fiber composites; plastics; and various materials used to form gaskets.

Embodiments of the invention can also include one or more of the following features. For example, the diameter of at least one of the simultaneously drilled holes can be 0.01 inches, and the diameter of at least another of the simultaneously drilled holes can be 0.06 inches. The plurality of simultaneously drilled holes in a work piece can be a plurality of angled, diamond-shaped holes. The plurality of simultaneously drilled holes in a work piece can be a plurality of circularly-, elliptically-, rectangularly- or triangularly-shaped holes, which can be drilled normal to, or angled to a surface of the work piece. The plurality of simultaneously drilled holes in a work piece can also be a plurality of any combination of circularly-, elliptically-, rectangularly- or triangularly-shaped holes. A first hole drilled can have a first center, and a second hole drilled can have a second center, and the distance from the first center to the second center can be approximately 0.12 inches.

Embodiments of the invention can also include one or more of the following features. For example, the fluid jet cutting head can be moved while the high speed fluid and abrasive are being dispensed from the fluid outlet orifices of the fluid jet cutting head's nozzle.

Embodiments of the present invention provide one or more of the following advantages. Reducing the manufacturing process time, as a plurality of holes can be drilled simultaneously. The ability to drill a pattern of holes without moving a cutting head. A reduction in manufacturing processing time, as a result of decreased operations (activating an actuator, deactivating the actuator, positioning a cutting head) between successive hole drilling operations.

BRIEF DESCRIPTION OF THE DRAWINGS

The following drawings are illustrative of particular embodiments of the invention and therefore do not limit the scope of the invention. The drawings are not necessarily to scale (unless so stated) and are intended for use in conjunction with the explanations in the following detailed description. Embodiments of the invention will hereinafter be described in conjunction with the appended drawings, wherein like numerals denote like elements.

FIG. 1 is a perspective view of a fluid jet cutting system, according to some embodiments;

FIG. 2 is a side cross-sectional view of a fluid jet cutting head, according to some embodiments;

FIG. 3a is a perspective view of a nozzle, according to some embodiments;

FIG. 3b is a perspective view of a nozzle, according to some embodiments;

FIG. 3c is a perspective cross-sectional view of a nozzle, according to some embodiments;

FIG. 4a is a perspective view of a nozzle, according to some embodiments;

FIG. 4b is a perspective view of a nozzle, according to some embodiments;

FIG. 4c is a perspective cross-sectional view of a nozzle, according to some embodiments;

FIG. 5 is a perspective view of a nozzle, according to some embodiments;

FIG. 6 is a perspective view of a fluid jet cutting system, according to some embodiments;

FIG. 7 is a side cross-sectional view of a fluid jet cutting head, according to some embodiments.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following detailed description is exemplary in nature and is not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the following description provides some practical illustrations for implementing exemplary embodiments of the present invention. Examples of constructions, materials, dimensions, and manufacturing processes are provided for selected elements, and all other elements employ that which is known to those of ordinary skill in the field of the invention. Those skilled in the art will recognize that many of the noted examples have a variety of suitable alternatives.

In some embodiments, a high pressure fluid jet cutting system 20 can include a frame 22, a high-pressure fluid source 24, a cutting head 26, an abrasive source 32 and an actuator 34, as depicted in FIG. 1. In some embodiments, the frame 22 can support the high-pressure fluid source 24 and the abrasive source 32. In some embodiments, the high-pressure fluid source 24 and the abrasive source 32 can be supported separate from the frame 22, as diagrammatically depicted in FIG. 1.

High pressure fluid and abrasives are supplied to the cutting head 26 by the high-pressure fluid source 24 and the abrasive source 32 respectively, according to many embodiments. The high-pressure fluid source 24 can have a high pressure fluid supply line 46 that connects the high-pressure fluid source 24 to the cutting head 26, such that the high-pressure fluid source 24 can supply high pressure fluid to the cutting head 26. The actuator 34 can be supported by the frame 22 and connected, as an in-line on-off valve, to the high pressure fluid supply line 46. In this way, the actuator 34 can either permit, or deny high pressure fluid from flowing from the high-pressure fluid source 24 to the cutting head 26. The abrasive source 32 can have an abrasive source supply line 52 that connects the abrasive source 32 to the cutting head 26 so that abrasives can be supplied to the cutting head 26.

In different embodiments, the high pressure fluid jet cutting system 20 can include a controller 36 and the frame 22 can include a work bed 42 and a motion system 44. The work bed 42 can be adapted to receive and hold a work piece 54, such that the work piece 54 is held securely during a cutting operation (discussed in greater detail below). Once the cutting operation has concluded, the work piece 54 can be released. The work bed 42 can use any device suitable for releasably holding a work piece 54, which can include magnetic clamps, vacuum suction clamps, spring release clamps or other such devices useful for holding a work piece 54 to a work bed 42.

The cutting head 26 can be connected to the motion system 44 of the frame 22 such that the motion system 44 can move the cutting head 26, according to some embodiments. In some embodiments, the motion system 44 can include a three axis motion system that can move and position the cutting head 26, relative to the work bed 42, along any and/or all of the three axes X-Y-Z, as depicted in FIG. 1. The motion system 44 can be comprised of a carriage 58 which can be mounted to a gantry 60. In some embodiments, it may be desirable to control the angle of the cutting head 26 in one or both of the X-Z plane and/or in the Y-Z plane. Thus in some embodiments, the motion system 44 can be a 5-axes motion control of the cutting head 26: translational motion and control in three axes, and rotational motion and control in two axes.

In many embodiments, it may be desirable to coordinate the movements of the cutting head 26 along with permitting or denying the flow of high pressure fluid and abrasive. The controller 36 can be configured to consecutively or simultaneously control both the motion system 44 and the actuator 34. Any computing device suitable for controlling an actuator 34 as well as a 3-axes or a 5-axes motion system can be used. In some embodiments, the controller can be a laptop or desktop computer; in some embodiments, the controller can be a customized computing system.

In different embodiments, as depicted in FIG. 2, the fluid jet cutting head 26 includes a fluid inlet 56, an orifice 62, a mixing chamber 64, and a nozzle 66 all contained within a cutting head body 72. The body 72 can be comprised of metal or other material of suitable strength to contain the fluid inlet 56, orifice 62, mixing chamber 64, and the nozzle 66. For example, the body 72 can be made from grade 316 stainless steel, and can be capable of withstanding internal pressures up to 100,000 pounds per square inch (psi).

According to some embodiments, the high-pressure fluid source 24 can be configured to supply pressurized fluid to the fluid jet cutting head's orifice 62 through a pressurized fluid supply line 46 that is connected to the fluid jet cutting head's fluid inlet 56, as depicted in FIG. 1. The high-pressure fluid source 24 can comprise any of a variety of high-pressure fluid sources known in the art and that are commercially available (e.g., an intensifier, a mechanical pump, a servo-driven pump, etc.). In some embodiments, the high pressure fluid can be pressurized to at least 75,000 psi. In some embodiments, the high pressure fluid provided to the fluid jet cutting head orifice can be pressurized to 100,000 psi. In some embodiments, the high pressure fluid can be pressurized to substantially between 10,000 and 50,000 psi, which corresponds to the fluid pressures currently in use to drill composites, including carbon fiber composites; plastics; and various materials used to form gaskets. In some embodiments, the high pressure fluid can be pressurized to substantially between 50,000 and 100,000 psi, which corresponds to the fluid pressures currently in use to drill a metal. Fluid pressures in excess of 100,000 psi are also contemplated as technology advances make such fluid pressures available to fluid jet cutting systems. The high-pressure fluid source 24 can be provided with any fitting, coupling, or connector suitable for connecting the high-pressure fluid source 24 to a high pressure fluid supply line 46.

In some embodiments, the abrasive source 32 can be configured to supply abrasive to the fluid jet cutting head's mixing chamber 64 through an abrasive source supply line 52 connected to the chamber 64. The abrasive source 32 can comprise a bulk hopper adapted to hold abrasive material. Suitable abrasives include, for example, garnet, silicon carbide, aluminum oxide, boron nitride and the like. The abrasive source 32 can be provided with any fitting, coupling, or connector suitable for connecting the abrasive source 32 to an abrasive source supply line 52.

As depicted in FIG. 2, the fluid inlet 56 can be configured as a main bore in some embodiments, that is fluidly connected to the high pressure fluid supply line (46 in FIG. 1) and the orifice 62, and that has an inlet axis 74. The fluid inlet 56 can be provided with a fluid-tight threaded fitting 76 in order to accept a high pressure fluid supply line, which can include an inlet cap 82 adapted to receive a connector 84 of the high pressure fluid supply line. The inlet cap 82 can be threaded, or can be provided with a quarter- or half-turn fastening mechanism, or with any other suitable fastening mechanism designed to ensure a fluid-tight fitting for a high pressure fluid connection. Other arrangements of suitable connectors, fittings or couplings adapted to accept a high pressure fluid supply line are also possible.

In many embodiments, the orifice 62 can have a generally inverted funnel shape, with a very small inlet opening 86 and a larger outlet opening 92 that are both aligned with the inlet axis 74. The inlet opening 86 can be in fluid communication with the fluid inlet 56. Typically, inlet openings 86 can be in the order of 0.004 inches to 0.03 inches in diameter, for example 0.01 inches. In some embodiments, the orifice 62 can have an inlet opening 86 that is in the order of 0.002 to 0.01 inches in diameter, for example 0.003 inches. The orifice 62 can have an orifice axis 94 that can be aligned with the inlet axis 74. Generally, the orifice can be made from a very hard material, such as natural or synthetic diamond, sapphire or ruby.

According to some embodiments, the mixing chamber 64 can have a fluid jet inlet opening 96 and a fluid jet outlet opening 102 that are aligned with the orifice axis 94. The mixing chamber 64 can also have a transverse opening 104, that can typically be larger than the fluid jet openings 96, 102, and that can be adapted to be connected to an abrasive source supply line 52. The transverse opening 104 can be provided with any fitting, coupling, or connector suitable for connecting an abrasive source supply line 52 to a mixing chamber 64 opening.

In some embodiments, the nozzle 66 can have an elongated body 106 that has a body axis 112 which is aligned with both the inlet axis 74 and the orifice axis 94. The nozzle 66 can have a nozzle fluid inlet orifice 114 that is in fluid communication with the fluid jet outlet opening 102, and that is axially aligned with the body axis 112. In some embodiments, the high pressure fluid jet nozzle 66 can be made of carbide.

In many embodiments, the nozzle 66 can have an elongated body 106 that includes a body axis 112, a nozzle fluid inlet orifice 114 in fluid communication with the mixing chamber 64 and a plurality of conduits 116, as depicted in FIGS. 3A-3C and 4A-4C. The elongated body 106 can have an inlet face 122 and an outlet face 124. The inlet face 122 and the outlet face 124 can be substantially normal to the body axis 112. The elongated nozzle body 106 can contain a plurality of conduits 116. Each of the conduits 116 can be straight, and can have a conduit axis 126. Near the inlet face 122, the conduits 116 can all combine to form the nozzle fluid inlet orifice 114; the interior surface contours of the conduits 116 can be blended together such that the nozzle fluid inlet orifice 114 can be substantially circular at the inlet face 122. In this manner, each of the conduits 116 can be in fluid communication with the nozzle fluid inlet orifice 114.

In some embodiments, each of the conduit axes 126 can form an angle 132 with the body axis 112. In many embodiments, the angle 132 formed by a conduit axis 126 and the body axis 112 can be approximately two degrees. In some embodiments, the angle 132 formed by a conduit axis 126 and the body axis 112 can be substantially zero degrees.

Over the length of the elongated body 106, the angle 132 results in each of the conduits 116 forming its own fluid outlet orifice 134 on the outlet face 124 of the elongated body 106, and as a result, each of the conduits 116 can be in fluid communication with its own fluid outlet orifice 134. In some embodiments, the fluid outlet orifices 134 can be positioned on the outlet face 124 such that each of the fluid outlet orifices 134 can be symmetrically placed about the center of the outlet face 124. In some embodiments, the fluid outlet orifices 134 can be positioned on the outlet face 124 such that each fluid outlet orifice 134 substantially locates one of six vertices of a hexagon, as depicted in FIG. 4B. A seventh fluid outlet orifice 134 can be located in the center of the hexagon. In some embodiments, the fluid outlet orifices 134 can be positioned on the outlet face 124 such that each of the fluid outlet orifices 134 can be asymmetrically placed about the center of the outlet face 124. In some embodiments, the fluid outlet orifices 134 can be positioned on the outlet face 124 such that each fluid outlet orifice 134 substantially locates vertices and endpoints of a “W”, as depicted in FIG. 5. To form the “W” arrangement, a first angle 132 formed by a first conduit axis 126 and the body axis 112 can be greater than a second angle 132 formed by a second conduit axis 126 and the body axis 112. In some embodiments, the positioning of the fluid outlet orifices on the outlet face can also be determined by the shape requirements of a finished work piece, so that, for example, if a star-shaped hole pattern was required, the fluid outlet orifices can be positioned on the outlet face in a star-shaped pattern. In some embodiments, a portion of the nozzle 66 can have a rectangular cross sectional shape.

In some embodiments, the plurality of conduits can all have the same cross sectional shape (e.g., circular, elliptical, diamond, rectangular, triangular, etc.). In some embodiments, the plurality of conduits within a nozzle can include a mixture of cross sectional shapes. For example, two conduits can have a circular cross sectional shape, and two conduits can have a diamond cross sectional shape. Other combinations of cross sectional shaped conduits within a nozzle are also possible. The diameter of conduits with a circular cross sectional shape can be between approximately 0.01 inches and approximately 0.06 inches. Some embodiments include conduits with circular cross sectional shapes that have different diameters (e.g., one or more of the conduits have a diameter of 0.02 inches, and one or more of the conduits have a diameter of 0.05 inches). The cross sectional shape of a conduit can be determined by the shape requirements of a finished work piece, so that, for example, if a rectangularly shaped hole was required, a nozzle can have a conduit with a rectangular cross sectional shape.

In use, according to some embodiments, the high-pressure fluid source 24 can supply high pressure fluid to the high pressure fluid supply line 46. The actuator 34, which can act as an in-line on-off valve for the high pressure fluid supply line 46, can thus control the flow of pressurized fluid from the high-pressure fluid source 24 to the fluid inlet 56. In this way, the actuator 34 can either permit, or deny high pressure fluid from flowing from the high-pressure fluid source 24 to the cutting head 26.

High pressure fluid can enter the cutting head 26 at the fluid inlet 56 according to many embodiments. As the fluid moves through the fluid inlet 56, it is directed to the orifice 62, which as described above, has a very small inlet opening 86. As the fluid passes through the inlet opening 86, the velocity of the fluid increases and fluid pressure correspondingly decreases. This is due to the Venturi effect because the cross sectional area of the inlet opening 86 is smaller than the cross sectional area of the fluid inlet 56. As a result of the fluid pressure and the ratio of cross sectional areas, the fluid exiting the orifice 62 can be traveling at about 900 miles per hour, and can be best characterized as a fluid jet stream.

Another result of the Venturi effect is that during fluid flow, a vacuum can be created on the downstream side of the orifice 62, which is within the mixing chamber 64, according to some embodiments. The vacuum can tend to draw abrasives out of the abrasive source supply line 52 and into the mixing chamber 64. In this manner, the abrasive source 32 can supply abrasives to the mixing chamber 64 via the abrasive source supply line 52. Once in the mixing chamber, the abrasives can become mixed within the fluid of the fluid jet, which can now be described as an abrasive fluid jet stream.

Another result of the Venturi effect is that when the fluid flow stops, the vacuum created on the downstream side of the orifice also stops. Thus, in some embodiments, when the fluid flow through the high pressure fluid supply line is denied by the actuator, the flow of abrasives from the abrasive source can also be stopped because the vacuum drawing in the abrasives is no longer present.

In some embodiments, downstream of the mixing chamber 64 is the nozzle 66. One of the functions of the nozzle can be to permit the abrasives to accelerate to match the fluid velocity. Other functions of the nozzle can be to focus and direct the abrasive fluid jet stream.

In many embodiments, the abrasive fluid jet stream can be divided into several abrasive fluid jet streams due to the presence of conduits within the nozzle. Conduits 116 within the nozzle body 106 divert the single abrasive fluid jet stream, coming from the mixing chamber's fluid jet outlet opening 102, into a plurality of abrasive fluid jet streams, one for each conduit 116 within the nozzle body 106.

In some embodiments, a method of drilling a plurality of holes into a work piece 54 can include activating the actuator 34 of the fluid jet cutting system 20, thereby dispensing high speed fluid and abrasive (an abrasive fluid jet stream) from the fluid outlet orifices 134 of the fluid jet cutting head's nozzle 66. The fluid outlet orifices 134 are thus each configured to provide a fluid jet cutting stream, such that each fluid jet cutting stream from each of the fluid outlet orifices 134 can simultaneously drill a plurality of holes into the work piece 54.

According to different embodiments, a substantial time savings can be realized. Consider the following two scenarios that summarize the time required to drill using a traditional water jet drilling procedure as compared with the time required to drill using equipment, according to embodiments described herein. In a traditional water jet drilling procedure, a controller can activate an actuator to start an abrasive fluid jet stream. A single hole is drilled. The controller can then de-activate the actuator to stop the abrasive fluid jet stream. The controller then can move the cutting head to a next position, and the process can repeat in order to drill an additional hole. In this manner, the time required to drill a single hole can include the time to drill the hole, the time for the actuator to be cycled on once and off once, and the time for the cutting head to be repositioned once. According to embodiments described herein, a plurality of holes can be drilled simultaneously from a single nozzle, for example, seven holes. In such an embodiment, a controller can activate an actuator, starting an abrasive fluid jet stream. Seven holes can simultaneously be drilled. The controller can then de-activate the actuator, which can stop the abrasive fluid jet stream. The controller then can move the cutting head to the next position, and the process can repeat in order to drill an additional seven holes. In this manner, the time required to drill seven holes can include the time to drill the seven simultaneously-drilled holes, the time for the actuator to be cycled on once and off once, and the time for the cutting head to be repositioned once. The result is a substantial time savings as compared with the traditional water jet drilling procedure.

The equipment, according to embodiments described herein, and operated in a manner that accords with methods described herein, can produce a variety of different hole configurations in a variety of different work pieces. In some embodiments, the diameter of at least one of the simultaneously drilled holes can be 0.01 inches, and the diameter of at least one of the other simultaneously drilled holes can be 0.06 inches. Such an outcome can be obtained by, for example, using a nozzle embodiment that has one conduit that is less than 0.06 inches in diameter, and at least one other conduit that is less than 0.01 inches in diameter.

In some embodiments, the plurality of holes drilled in the work piece can comprise a plurality of angled, diamond-shaped holes. Such a drilled hole pattern can be achieved through the use of a 4- or 5-axis motion system 44 with a controller 36 that is configured to control both the motion system 44 and the actuator 34. In some embodiments, the plurality of simultaneously drilled holes in a work piece can be a plurality of circularly-, elliptically-, rectangularly- or triangularly-shaped holes, which can be drilled normal to, or angled to a surface of the work piece. In some embodiments, the plurality of simultaneously drilled holes in a work piece can be a plurality of any combination of circularly-, elliptically-, rectangularly- or triangularly-shaped holes.

In many embodiments, it may be desirable to simultaneously drill a plurality of small holes in a work piece, then, once the holes have been drilled through the work piece, a controller can coordinate the movement of the cutting head so as to enlarge the diameter of the holes. In this manner, the drilled holes can be sized to a finished dimension that is larger than the dimension of the abrasive fluid jet stream. In some embodiments, the center to center distance of two simultaneously drilled holes can be approximately 0.12 inches.

In some embodiments, the fluid jet cutting head 26 can includes a second fluid inlet 142, a second orifice 144, a second mixing chamber 146, and a second nozzle 148, all contained within the cutting head body 72, as depicted in FIGS. 6-7. Such an arrangement can be in accordance with the teachings of commonly assigned U.S. patent application Ser. No. 12/388,355 entitled “Multi-Head Fluid Jet Cutting System” and filed on Feb. 18, 2009, which is hereby incorporated by reference herein in its entirety. The high-pressure fluid source 24 can have a second high pressure fluid supply line 152 that connects the high-pressure fluid source 24 to the second fluid inlet 142 such that the high-pressure fluid source 24 can supply a second source of high pressure fluid to the cutting head 26. The high pressure fluid jet cutting system 150 can include a second actuator 154, that is coupled to the frame 22. The second actuator 154 can be supported by the frame 22 and connected, as an in-line on-off valve, to the second high pressure fluid supply line 152. In this way, the second actuator 154 can either permit, or deny high pressure fluid from flowing from the high-pressure fluid source 24 to the second fluid inlet 142, and a second fluid jet stream can be formed. The abrasive source 32 can have a second abrasive source supply line 156 that connects the abrasive source 32 to the second mixing chamber 146 so that abrasives can be supplied to the second fluid jet stream forming a second abrasive fluid jet stream.

In many embodiments, the second abrasive fluid jet stream can be divided into several abrasive fluid jet streams due to the presence of conduits within the second nozzle, as is discussed elsewhere herein. Conduits within the nozzle body divert the second abrasive fluid jet stream, coming from the second mixing chamber outlet, into a plurality of abrasive fluid jet streams, one for each conduit within the second nozzle. In such an embodiment, a plurality of holes can simultaneously be drilled from each of the two nozzles attached to the single cutting head.

Likewise, in accordance with the teachings of commonly assigned U.S. patent application Ser. No. 12/388,355 entitled “Multi-Head Fluid Jet Cutting System” and filed on Feb. 18, 2009, additional abrasive fluid jet streams can be formed within the single cutting head 26 by including additional fluid inlets, orifices, mixing chambers, and nozzles contained within the cutting head body 72, and providing additional actuators, high pressure fluid supply lines and abrasive source supply lines.

In some embodiments, the nozzle can be used in conjunction with a cutting head in accordance with the teachings of commonly assigned U.S. Pat. No. 6,846,221 entitled “Adaptive Nozzle System for High-Energy Abrasive Stream Cutting” patented on Jan. 25, 2005, which is hereby incorporated by reference herein in its entirety. In such embodiments, the orientation of the nozzle can be rotated so that an additional plurality of holes can simultaneously be drilled without moving the cutting head to a new position relative to the work piece. For example, after drilling the “W” pattern of holes that can be simultaneously drilled using the nozzle depicted in FIG. 5, the nozzle can be rotated 180 degrees and an upside down “W” pattern of holes can also simultaneously be drilled in the work piece. In this manner, a pattern of ten holes can be drilled without moving and repositioning the cutting head. In some applications, this can produce a work piece with a closely-packed arrangement of holes, that can be obtained with a minimum of cutting head movement, resulting in a more efficient use of equipment processing time. Other embodiments that combine the teachings of this disclosure with that of U.S. Pat. No. 6,846,221 are also possible, which can result in additional advantages.

In the foregoing detailed description, the invention has been described with reference to specific embodiments. However, it may be appreciated that various modifications and changes can be made without departing from the scope of the invention as set forth in the appended claims.

Claims

1. A high pressure fluid jet cutting system comprising:

a frame;

a fluid jet cutting head coupled to the frame, the fluid jet cutting head including: a fluid inlet; an orifice in fluid communication with the fluid inlet; a mixing chamber in fluid communication with the orifice; and a nozzle with an elongated body that comprises: a body axis, a fluid inlet orifice in fluid communication with the cutting head's mixing chamber, and a plurality of conduits, wherein each of the plurality of conduits (a) is in fluid communication with the fluid inlet orifice, (b) has its own conduit axis that forms an angle with the body axis, and (c) is in fluid communication with its own fluid outlet orifice;

a high-pressure fluid source including a pressurized fluid supply line connected to the fluid jet cutting head's fluid inlet and configured to supply pressurized fluid to the fluid jet cutting head's fluid inlet;

an abrasive source including an abrasive source supply line connected to the fluid jet cutting head's mixing chamber and configured to supply abrasive to the fluid jet cutting head's mixing chamber; and

an actuator coupled to the frame, the actuator being configured to control flow of pressurized fluid from the high-pressure fluid source to the fluid jet cutting head's fluid inlet.

2. The high pressure fluid jet cutting system of claim 1, wherein a first angle formed by a first conduit axis and the body axis is substantially zero degrees, and a second angle formed by a second conduit axis and the body axis is greater than a third angle formed by a third conduit axis and the body axis.

3. The high pressure fluid jet cutting system of claim 1, wherein the high-pressure fluid source is configured to supply pressurized fluid that is pressurized to substantially between 50,000 and 100,000 pounds per square inch and wherein the orifice is adapted to withstand fluid that is pressurized to substantially between 50,000 and 100,000 pounds per square inch.

4. The high pressure fluid jet cutting system of claim 1, wherein the fluid jet cutting head further includes:

a second fluid inlet;

a second orifice in fluid communication with the second fluid inlet;

a second mixing chamber in fluid communication with the second orifice; and

a second nozzle with a second-nozzle elongated body that comprises: a second-nozzle body axis, a second-nozzle fluid inlet orifice in fluid communication with the second mixing chamber, and a plurality of second-nozzle conduits, wherein each of the plurality of second-nozzle conduits (a) is in fluid communication with the second-nozzle fluid inlet orifice, (b) has its own second-nozzle conduit axis that forms a second angle with the body axis, and (c) is in fluid communication with its own second-nozzle fluid outlet orifice; and

wherein the high-pressure fluid source includes a second pressurized fluid supply line connected to the fluid jet cutting head's second fluid inlet and configured to supply pressurized fluid to the fluid jet cutting head's second fluid inlet;

wherein the abrasive source includes a second abrasive source supply line connected to the fluid jet cutting head's second mixing chamber and configured to supply abrasive to the fluid jet cutting head's second mixing chamber; and

wherein the high pressure fluid jet cutting system further comprises a second actuator, the second actuator coupled to the frame, the second actuator in fluid communication with the high-pressure fluid source and the second fluid inlet.

5. A fluid jet nozzle including an elongated body that comprises:

a body axis;

a fluid inlet orifice configured to be in fluid communication with a source of high speed fluid and abrasive;

a plurality of conduits, wherein each of the plurality of conduits (a) is in fluid communication with the fluid inlet orifice, (b) has its own conduit axis that forms an angle with the body axis, and (c) is in fluid communication with its own fluid outlet orifice.

6. The fluid jet nozzle of claim 5, wherein each of the plurality of conduits further (d) have a circular cross sectional shape, wherein a diameter of at least one conduit is approximately 0.01 inches, and a diameter of at least one other conduit is approximately 0.06 inches.

7. The fluid jet nozzle of claim 5, wherein the elongated body is made of carbide.

8. The fluid jet nozzle of claim 5, wherein a first angle formed by a first conduit axis and the body axis is greater than a second angle formed by a second conduit axis and the body axis.

9. The fluid jet nozzle of claim 5, wherein a first angle formed by a first conduit axis and the body axis is approximately two degrees.

10. The fluid jet nozzle of claim 5, further comprising:

an outlet face substantially normal to the body axis, the fluid outlet orifices disposed on the outlet face,

wherein the fluid outlet orifices are positioned on the outlet face such that each fluid outlet orifice substantially locates one of six vertices of a hexagon.

11. The fluid jet nozzle of claim 5, further comprising:

an outlet face substantially normal to the body axis, the fluid outlet orifices disposed on the outlet face,

wherein the fluid outlet orifices are positioned on the outlet face such that each fluid outlet orifice substantially locates vertices and endpoints of a “W”; and

wherein a portion of the elongated body has a rectangular cross sectional shape.

12. The fluid jet nozzle of claim 5, further comprising a cutting head connector adapted to attach the elongated body to a fluid jet cutting head, wherein the fluid outlet orifices are each configured to provide a fluid jet cutting stream.

13. A method of drilling a plurality of holes into a work piece comprising:

(a) providing a high pressure fluid jet cutting system comprising: (i) a fluid jet cutting head including a fluid inlet, an orifice in fluid communication with the fluid inlet, a mixing chamber in fluid communication with the orifice, and a nozzle with an elongated body that comprises: a body axis, a fluid inlet orifice in fluid communication with the fluid inlet, and a plurality of conduits, wherein each of the plurality of conduits (A) is in fluid communication with the fluid inlet orifice, (B) has its own conduit axis that forms an angle with the body axis, and (C) is in fluid communication with its own fluid outlet orifice, (ii) a high-pressure fluid source adapted to supply pressurized fluid to the fluid jet cutting head's fluid inlet, (iii) an abrasive source adapted to supply abrasive to the fluid jet cutting head's mixing chamber, and (iv) an actuator configured to control flow of pressurized fluid from the high-pressure fluid source to the fluid jet cutting head's fluid inlet,

(b) installing the work piece in the fluid jet cutting system; and

(c) activating the actuator of the fluid jet cutting system, thereby dispensing high speed fluid and abrasive from the fluid outlet orifices of the fluid jet cutting head's nozzle to simultaneously drill the plurality of holes into the work piece.

14. The method of claim 13, wherein the diameter of at least one of the drilled holes is 0.01 inches, and the diameter of at least one of the drilled holes is 0.06 inches.

15. The method of claim 13, wherein the plurality of holes drilled in the work piece comprise a plurality of angled, diamond-shaped holes.

16. The method of claim 13, wherein a first hole drilled has a first center, and a second hole drilled has a second center, and the distance from the first center to the second center is approximately 0.12 inches.

17. The method of claim 13, wherein the high pressure fluid supplied to the fluid jet cutting head's fluid inlet is pressurized to 100,000 pounds per square inch.

18. The method of claim 13, wherein the high pressure fluid supplied to the fluid jet cutting head's fluid inlet is pressurized to at least 75,000 pounds per square inch.

19. The method of claim 13, wherein the high pressure fluid supplied to the fluid jet cutting head's fluid inlet is pressurized to substantially between 50,000 and 100,000 pounds per square inch.

20. The method of claim 13, the method further comprising:

(d) moving the fluid jet cutting head while the high speed fluid and abrasive are being dispensed from the fluid outlet orifices of the fluid jet cutting head's nozzle.