ARNOLD AIR FORCE BASE, Tenn. –
Arnold Air Force Base’s model and machine shop team members felt the drilling process needed to be modernized.
The opportunity to realize this redesign arose in the fall of 2023, when the period for submitting ideas for the Arnold Engineering Development Complex Innovation Spark Tank program began.
An idea from Bob Williams, precision engineering shop manager at Arnold AFB, AEDC’s headquarters, was among the projects selected by the AEDC Spark Tank Board of Directors for an innovation grant. The award enabled pattern shop personnel to purchase improved drill bits to improve the efficiency and accuracy of functions regularly performed in the shop.
The Spark Tank proposal was prompted by an increased demand for drilling and honing work in the pattern shop. Williams wrote that shop employees were using “old” drilling equipment, which could lead to inefficiency and quality issues. He added that acquiring new technology to replace the outdated equipment would improve project flow and quality.
“I am grateful that our precision shop at AEDC now has this significantly improved drilling capacity,” said Warner Holt, contract group leader for test operations and maintenance for manufacturing services at Arnold AFB. “This technology upgrade through the Spark Tank program has allowed us to better serve our customers with a timely and quality-focused option that was not available to us before. The efficiency and improved quality we can now provide really makes a difference as we do our part every day to support today’s Soldiers.”
In machining, drilling is essentially the process of enlarging an existing hole or opening in a device or part. Honing, as used in the Williams Spark Tank application, is the process of smoothing the device surface where drilling has been done to achieve a correct shape and greater precision.
“Drilling and honing are inextricably linked when it comes to high-quality machining,” Williams’ post states. “High-speed drills with the latest insert technologies have a cleaner surface, free of pulled-out material and ready for honing, which lays the foundation for a high-quality surface after honing.”
The pressure exerted on a cylinder wall during a drilling operation is the main cause of bore distortion. Williams wrote that acquiring modernized equipment would help correct this problem.
“Using a new drilling system – a positive rake angle, a smaller radius drill bit to reduce cutting pressure during the drilling process – can reduce this stress,” Williams’ paper states. “This will improve efficiency and quality, which will be required due to increased demand.”
In the pattern shop, equipment parts are drilled to create a smoother surface for the flow of air or fluids or to provide precise openings that serve as connection points for other parts.
Leadman precision mechanic and AEDC Fellow Norman Smith said the new drilling system can be used on drilling machines already in the model shop.
“It can be installed on several different machines because the adapters we purchased fit any of our CAT 50 CNCs or CAT 40 CNCs (Caterpillar® V-flange Computer Numerical Controls). But we can also run it on manual machines, so it’s versatile throughout the shop,” said Smith.
The system, purchased by the Model Shop with funds from the Spark Tank, can be used to drill a wide range of sizes, from holes as small as a quarter inch in diameter to holes up to 14 inches in diameter.
In addition to offering greater accuracy across multiple depths and widths, the new system is designed to improve efficiency. The drill heads feature hole-gauging technology and integrated digital indicators that allow operators to quickly see if a hole meets specifications. Previously, this required operators to attach an indicator to the drill and manually determine if a hole was the desired dimensions.
“With this system here, you don’t have to do that anymore,” Smith said of the new system. “It will improve overall quality and save time.”
Drilling operations are performed an average of three days per week in Arnold AFB’s model and machine shop. According to Williams’ Spark Tank filing, the new system’s improved spindle speeds will increase productivity by 1.5 hours per day, which equates to about $295 in repurposed time per week.
“Demand for this unit is growing, so productivity will only increase over time,” Williams wrote.
Spark Tank is an annual Department of the Air Force event that provides an opportunity for military personnel, Department of Defense civilians, and contractors to showcase innovative solutions to difficult Air Force and Space Force problems. The Office of the Deputy Under Secretary of the Air Force, Management, and AFWERX established the Spark Tank Innovation Awards to recognize innovative solutions proposed and developed by employees across the enterprise. The awards are designed to encourage innovation development, talent retention, and accelerate the adoption of new technologies that impact the Air Force and Space Force.
The first Spark Tank event took place in 2018 and has been held annually since then.
The deadline for proposals for the 2024 AEDC Spark Tank was in January. The following month, the AEDC Spark Tank Board reviewed the submitted ideas, and those selected to present their ideas to the Spark Tank panel were paired with a team from the AEDC Continuous Improvements and Innovation group to help with the selection process. The idea contributors then presented their proposals to the Board, and feedback was provided on the proposals presented.
“Internal innovation allows Arnold AFB to proactively respond to new aerospace test challenges,” said Aaron Allen, AEDC innovation manager. “Whether it’s adapting to new regulatory requirements, addressing safety concerns or overcoming technical obstacles, internal innovation ensures the facility remains flexible and able to respond to changing circumstances.”
“Overall, internal innovation is instrumental in driving continuous improvement and ensuring Arnold AFB remains at the forefront of aerospace testing and technology developments.”
