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NASA NTRS2007

Self-Advancing Step-Tap Drills

Self-advancing tool bits that are hybrids of drills and stepped taps make it possible to form threaded holes wider than about 1/2 in. (about 13 mm) without applying any more axial force than is necessary for forming narrower pilot holes. These self-advancing stepped-tap drills were invented for use by space-suited astronauts performing repairs on reinforced carbon/carbon space-shuttle leading edges during space walks, in which the ability to apply axial drilling forces is severely limited. Self-advancing stepped-tap drills could also be used on Earth for making wide holes without applying large axial forces. A self-advancing stepped-tap drill (see figure) includes several sections having progressively larger diameters, typically in increments between 0.030 and 0.060 in. (between about 0.8 and about 1.5 mm). The tip section, which is the narrowest, is a pilot drill bit that typically has a diameter between 1/8 and 3/16 in. (between about 3.2 and about 4.8 mm). The length of the pilot-drill section is chosen, according to the thickness of the object to be drilled and tapped, so that the pilot hole is completed before engagement of the first tap section. Provided that the cutting-edge geometry of the drill bit is optimized for the material to be drilled, only a relatively small axial force [typically of the order of a few pounds (of the order of 10 newtons)] must be applied during drilling of the pilot hole. Once the first tap section engages the pilot hole, it is no longer necessary for the drill operator to apply axial force: the thread engagement between the tap and the workpiece provides the axial force to advance the tool bit. Like the pilot-drill section, each tap section must be long enough to complete its hole before engagement of the next, slightly wider tap section. The precise values of the increments in diameter, the thread pitch, the rake angle of the tap cutting edge, and other geometric parameters of the tap sections must be chosen, in consideration of the workpiece material and thickness, to prevent stripping of threads during the drilling/tapping operation. A stop-lip or shoulder at the shank end of the widest tap section prevents further passage of the tool bit through the hole.

Pettit, Donald R.↗

NASA NTRS2010

Results from Testing of Two Rotary Percussive Drilling Systems

The developmental test program for the MSL (Mars Science Laboratory) rotary percussive drill examined the e ect of various drill input parameters on the drill pene- tration rate. Some of the input parameters tested were drill angle with respect to gravity and percussive impact energy. The suite of rocks tested ranged from a high strength basalt to soft Kaolinite clay. We developed a hole start routine to reduce high sideloads from bit walk. The ongoing development test program for the IMSAH (Integrated Mars Sample Acquisition and Handling) rotary percussive corer uses many of the same rocks as the MSL suite. An additional performance parameter is core integrity. The MSL development test drill and the IMSAH test drill use similar hardware to provide rotation and percussion. However, the MSL test drill uses external stabilizers, while the IMSAH test drill does not have external stabilization. In addition the IMSAH drill is a core drill, while the MSL drill uses a solid powdering bit. Results from the testing of these two related drilling systems is examined.

Kriechbaum, Kristopher↗

NASA NTRS2022

Compressed CO2 Hard Rock Drill for Mars

We have developed a down-the-hole (DTH) rotary-percussive drill prototype that could operate on compressed Mars atmospheric CO2 gas with a wireline drilling approach. This technology addresses a need for more aggressive sampling and drilling techniques, for both scientific purposes and to obtain In-Situ Resource Utilization (ISRU) resources for future NASA missions and human crew support. Using a spool of lightweight, high-pressure capillary, a DTH drill assembly would be moved in and out of the hole that could be a kilometer or more in depth. The CO2 drill is designed so that Mars atmospheric CO2 could be collected, compressed, and supplied down the hole and routed through microducts, valves, and reservoirs for the purpose of controlling miniature mechanical actuation in the assembly. By using compressed CO2, the drill system avoids the need for heavy electrical cabling and actuator systems or a liquid media for carrying away particulates as is typically used in terrestrial drilling systems. Instead, the liquid CO2 that powers the drill expands to a gas and could be channeled around the drill housing to carry cuttings to be collected in a bailing bucket. Where terrestrial systems often use drill depth vs time as a metric, a Mars drilling system would need to be extremely low mass, but would have no need to perform under tight schedules. In this paper, we will document our trade studies, progression for the design of microduct logic verified through multiple generations of prototypes, and provide predictive performance data on energy consumption, hole depth, and drill time.

Wilcox, Brian↗

NASA NTRS2022

Compressed CO2 Hard Rock Drill for Mars

Wilcox, Brian↗

NASA NTRSDate not supplied

Automation and AI in Space Drilling

Future planetary surface sampling missions, such as delving past the near-surface ice layers on Mars in search of organics and possibly signs of past/extant life, will require lightweight, low-mass planetary drilling and sample handling. Unlike terrestrial drills, these exploration drills must work dry (without drilling muds or gas), blind (no prior local or regional seismic or other surveys), and light (very low downward force or weight on bit, and perhaps 100 W available from solar power or batteries). Given the lightspeed transmission delays to Mars and outward, an exploratory planetary drill cannot be controlled directly from Earth. Drills that penetrate deeper than a few centimeters are likely to get stuck if operated open-loop (the MSL drill only penetrates 5 cm, and the MER Rock Abrasion Tools 5 mm by comparison), so some form of local drill control is required. In the relatively near-term, human crews cannot be presumed to be available for surface instrument teleoperation. Therefore highly automated drill and sample-transfer operations will be required, to explore the subsurface with the ability to safe robotic drilling systems and recover and continue on from the most probable fault conditions. Current automation, scheduling and diagnostic approaches will be discussed that roughly track the actions and roles of humans in terrestrial manual drilling operations.

drill automation↗

NASA NTRS2011

Testing and Development of a Percussive Augmenter for Rotary Drills

Hammering drills are effective in fracturing the drilled medium while rotary drills remove cuttings. The combination provides a highly effective penetration mechanism. Piezoelectric actuators were integrated into an adapter to produce ultrasonic percussion; augmenting rotary drilling. The drill is capable of operating at low power, low applied force and, with proper tuning, low noise. These characteristics are of great interest for future NASA missions and the construction/remodeling industry. The developed augmenter connects a commercially available drill and bit and was tested to demonstrate its capability. Input power to the drill was read using a multimeter and the augmenter received a separate input voltage. The drive frequency of the piezoelectric actuator was controlled by a hill climb algorithm that optimizes and records average power usage to operate the drill at resonating frequency. Testing the rotary drill and augmenter across a range of combinations with total power constant at 160 Watts has shown results in concrete and limestone samples that are as good as or better than the commercial drill. The drill rate was increased 1.5 to over 10 times when compared to rotation alone.

rotary-hammering↗

NASA NTRS2010

Ultrasonic/Sonic Rotary-Hammer Drills

Ultrasonic/sonic rotary-hammer drill (USRoHD) is a recent addition to the collection of apparatuses based on ultrasonic/sonic drill corer (USDC). As described below, the USRoHD has several features, not present in a basic USDC, that increase efficiency and provide some redundancy against partial failure. USDCs and related apparatuses were conceived for boring into, and/or acquiring samples of, rock or other hard, brittle materials of geological interest. They have been described in numerous previous NASA Tech Briefs articles. To recapitulate: A USDC can be characterized as a lightweight, lowpower, piezoelectrically driven jackhammer in which ultrasonic and sonic vibrations are generated and coupled to a tool bit. A basic USDC includes a piezoelectric stack, an ultrasonic transducer horn connected to the stack, a free mass ( free in the sense that it can bounce axially a short distance between hard stops on the horn and the bit), and a tool bit. The piezoelectric stack creates ultrasonic vibrations that are mechanically amplified by the horn. The bouncing of the free mass between the hard stops generates the sonic vibrations. The combination of ultrasonic and sonic vibrations gives rise to a hammering action (and a resulting chiseling action at the tip of the tool bit) that is more effective for drilling than is the microhammering action of ultrasonic vibrations alone. The hammering and chiseling actions are so effective that unlike in conventional twist drilling, little applied axial force is needed to make the apparatus advance into the material of interest. There are numerous potential applications for USDCs and related apparatuses in geological exploration on Earth and on remote planets. In early USDC experiments, it was observed that accumulation of cuttings in a drilled hole causes the rate of penetration of the USDC to decrease steeply with depth, and that the rate of penetration can be increased by removing the cuttings. The USRoHD concept provides for removal of cuttings in the same manner as that of a twist drill: An USRoHD includes a USDC and a motor with gearhead (see figure). The USDC provides the bit hammering and the motor provides the bit rotation. Like a twist drill bit, the shank of the tool bit of the USRoHD is fluted. As in the operation of a twist drill, the rotation of the fluted drill bit removes cuttings from the drilled hole. The USRoHD tool bit is tipped with a replaceable crown having cutting teeth on its front surface. The teeth are shaped to promote fracturing of the rock face through a combination of hammering and rotation of the tool bit. Helical channels on the outer cylindrical surface of the crown serve as a continuation of the fluted surface of the shank, helping to remove cuttings. In the event of a failure of the USDC, the USRoHD can continue to operate with reduced efficiency as a twist drill. Similarly, in the event of a failure of the gearmotor, the USRoHD can continue to operate with reduced efficiency as a USDC.

Badescu, Mircea↗

NASA NTRS2006

Drilling Automation Demonstrations in Subsurface Exploration for Astrobiology

This project proposes to study subsurface permafrost microbial habitats at a relevant Arctic Mars-analog site (Haughton Crater, Devon Island, Canada) while developing and maturing the subsurface drilling and drilling automation technologies that will be required by post-2010 missions. It builds on earlier drilling technology projects to add permafrost and ice-drilling capabilities to 5m with a lightweight drill that will be automatically monitored and controlled in-situ. Frozen cores obtained with this drill under sterilized protocols will be used in testing three hypotheses pertaining to near-surface physical geology and ground H2O ice distribution, viewed as a habitat for microbial life in subsurface ice and ice-consolidated sediments. Automation technologies employed will demonstrate hands-off diagnostics and drill control, using novel vibrational dynamical analysis methods and model-based reasoning to monitor and identify drilling fault states before and during faults. Three field deployments, to a Mars-analog site with frozen impact crater fallback breccia, will support science goals, provide a rigorous test of drilling automation and lightweight permafrost drilling, and leverage past experience with the field site s particular logistics.

Glass, Brian↗

NASA NTRS2012

Mars Science Laboratory Drill

This drill (see Figure 1) is the primary sample acquisition element of the Mars Science Laboratory (MSL) that collects powdered samples from various types of rock (from clays to massive basalts) at depths up to 50 mm below the surface. A rotary-percussive sample acquisition device was developed with an emphasis on toughness and robustness to handle the harsh environment on Mars. It is the first rover-based sample acquisition device to be flight-qualified (see Figure 2). This drill features an autonomous tool change-out on a mobile robot, and novel voice-coil-based percussion. The drill comprises seven subelements. Starting at the end of the drill, there is a bit assembly that cuts the rock and collects the sample. Supporting the bit is a subassembly comprising a chuck mechanism to engage and release the new and worn bits, respectively, and a spindle mechanism to rotate the bit. Just aft of that is a percussion mechanism, which generates hammer blows to break the rock and create the dynamic environment used to flow the powdered sample. These components are mounted to a translation mechanism, which provides linear motion and senses weight-on-bit with a force sensor. There is a passive-contact sensor/stabilizer mechanism that secures the drill fs position on the rock surface, and flex harness management hardware to provide the power and signals to the translating components. The drill housing serves as the primary structure of the turret, to which the additional tools and instruments are attached. The drill bit assembly (DBA) is a passive device that is rotated and hammered in order to cut rock (i.e. science targets) and collect the cuttings (powder) in a sample chamber until ready for transfer to the CHIMRA (Collection and Handling for Interior Martian Rock Analysis). The DBA consists of a 5/8-in. (.1.6- cm) commercial hammer drill bit whose shank has been turned down and machined with deep flutes designed for aggressive cutting removal. Surrounding the shank of the bit is a thick-walled maraging steel collection tube allowing the powdered sample to be augured up the hole into the sample chamber. For robustness, the wall thickness of the DBA was maximized while still ensuring effective sample collection. There are four recesses in the bit tube that are used to retain the fresh bits in their bit box. The rotating bit is supported by a back-to-back duplex bearing pair within a housing that is connected to the outer DBA housing by two titanium diaphragms. The only bearings on the drill in the sample flow are protected by a spring-energized seal, and an integrated shield that diverts the ingested powdered sample from the moving interface. The DBA diaphragms provide radial constraint of the rotating bit and form the sample chambers. Between the diaphragms there is a sample exit tube from which the sample is transferred to the CHIMRA. To ensure that the entire collected sample is retained, no matter the orientation of the drill with respect to gravity during sampling, the pass-through from the forward to the aft chamber resides opposite to the exit tube.

Okon, Avi B.↗

NASA NTRS2011

Percussive Augmenter of Rotary Drills (PARoD)

A percussive augmenter is being developed and it is designed to add ultrasonic hammering to a conventional commercial rotary drill through an adapter using a piezoelectric actuator. The combination of ultrasonic hammering and rotation creates a drill that requires low power and low axial load while providing faster penetration than conventional rotary-only drills. These characteristics make percussive augmentation of rotary drills ideal for not only planetary exploration but commercial applications as well. The purpose of this internship was to produce, test, and optimize an augmenter that drives a 2 inch diameter bit. This task was part of the percussive augmenter's phase II of an ongoing contract and it involved increasing the capability of the .25 inch version of the augmenter prototype that was developed in phase I. Due to fabrication delays of the augmenter, an extensive part of the test effort was conducted using previous rotary and hammer drill prototypes. These tests focused on drilling deep over long periods of time to provide for effective stress test of the drill. Modifications were made to the drill, its components, and the testing procedure to achieve desired borehole depths. These results were used to start initial testing on the 2 inch augmenter and provide preliminary data on the augmenter's ability to significantly improve penetration rate over conventional rotary-only drills.

rotraty hammer↗

NASA NTRS2015

Impact of Drilling Operations on Lunar Volatiles Capture: Thermal Vacuum Tests

In Situ Resource Utilization (ISRU) enables future planetary exploration by using local resources to supply mission consumables. This idea of 'living off the land' has the potential to reduce mission cost and risk. On the moon, water has been identified as a potential resource (for life support or propellant) at the lunar poles, where it exists as ice in the subsurface. However, the depth and content of this resource has yet to be confirmed on the ground; only remote detection data exists. The upcoming Resource Prospector mission (RP) will 'ground-truth' the water using a rover, drill, and the RESOLVE science package. As the 2020 planned mission date nears, component level hardware is being tested in relevant lunar conditions (thermal vacuum). In August 2014 a series of drilling tests were performed using the Honeybee Robotics Lunar Prospecting Drill inside a 'dirty' thermal vacuum chamber at the NASA Glenn Research Center. The drill used a unique auger design to capture and retain the lunar regolith simulant. The goal of these tests was to investigate volatiles (water) loss during drilling and sample transfer to a sample crucible in order to validate this regolith sampling method. Twelve soil samples were captured over the course of two tests at pressures of 10(exp-5) Torr and ambient temperatures between -80C to -20C. Each sample was obtained from a depth of 40 cm to 50 cm within a cryogenically frozen bed of NU-LHT-3M lunar regolith simulant doped with 5 wt% water. Upon acquisition, each sample was transferred and hermetically sealed inside a crucible. The samples were later baked out to determine water wt% and in turn volatile loss by following ASTM standard practices. Of the twelve tests, four sealed properly and lost an average of 30% of their available water during drilling and transfer. The variability in the results correlated well with ambient temperature (lower the temperature lower volatiles loss) and the trend agreed with the sublimation rates for the same temperature. Moisture retention also correlated with quantity of sample: a larger amount of material resulted in less water loss. The drilling process took an average of 10 minutes to capture and transfer each sample. The drilling power was approximately 20 Watt with a Weight on Bit of approximately 30 N. The bit temperature indicated little heat input into formation during the drilling process.

drilling↗

NASA NTRS2012

Single Piezo-Actuator Rotary-Hammering (SPaRH) Drill

The search for present or past life in the Universe is one of the most important objectives of NASA's exploration missions. Drills for subsurface sampling of rocks, ice and permafrost are an essential tool for astrobiology studies on other planets. Increasingly, it is recognized that drilling via a combination of rotation and hammering offers an efficient and effective rapid penetration mechanism. The rotation provides an intrinsic method for removal of cuttings from the borehole while the impact and shear forces aids in the fracturing of the penetrated medium. Conventional drills that use a single actuator are based on a complex mechanism with many parts and their use in future mission involves greater risk of failure and/or may require lubrication that can introduce contamination. In this paper, a compact drill is reported that uses a single piezoelectric actuator to produce hammering and rotation of the bit. A horn with asymmetric grooves was design to impart a longitudinal (hammering) and transverse force (rotation) to a keyed free mass. The drill requires low axial pre-load since the hammering-impacts fracture the rock under the bit kerf and rotate the bit to remove the powdered cuttings while augmenting the rock fracture via shear forces. The vibrations 'fluidize' the powdered cuttings inside the flutes reducing the friction with the auger surface. This action reduces the consumed power and heating of the drilled medium helping to preserve the pristine content of the acquired samples. The drill consists of an actuator that simultaneously impacts and rotates the bit by applying force and torque via a single piezoelectric stack actuator without the need for a gearbox or lever mechanism. This can reduce the development/fabrication cost and complexity. In this paper, the drill mechanism will be described and the test results will be reported and discussed.

ultrasonic impacts↗

NASA NTRS2013

Wireline Deep Drill for the Exploration of Icy Bodies

One of the most pressing current questions in space science is whether life has ever arisen anywhere else in the universe. Water is a critical prerequisite for all life-as-we-know-it, thus the possible exploration targets for extraterrestrial life are bodies that have or had copious liquid: Mars, Europa, and Enceladus. Due to the oxidizing nature of Mars' surface, as well as subsurface liquid water reservoirs present on Europa and Enceladus, the search for evidence of existing life must likely focus on subsurface locations, at depths sufficient to support liquid water or retain biologic signatures. To address these questions, an Auto-Gopher sampler has been developed that is a wireline type drill. This drill is suspended on a tether and its motors and mechanisms are built into a tube that ends with a coring bit. The tether provides the mechanical connection to a rover/lander on a surface as well as power and data communication. Upon penetrating to a target depth, the drill is retracted from the borehole, the core is deposited into a sample transfer system, and the drill is lowered back into the hole. Wireline operation sidesteps one of the major drawbacks of traditional continuous drill string systems by obviating the need for multiple drill sections, which add significantly to the mass and the complexity of the system (i.e. penetration rate was 40 cm per hour). Drilling to 2 meter depth and recovering of cores every 10 cm took a total time of 15 hours (a single step of drilling 10 cm and retrieving the core was 45 minutes). Total energy to reach the 2 m depth was 500 Whr. The Weight on Bit was limited to less than 70 Newton. The core recovery was 100%.

sampling↗

NASA NTRS1989

Lunar deep drill apparatus

A self contained, mobile drilling and coring system was designed to operate on the Lunar surface and be controlled remotely from earth. The system uses SKITTER (Spatial Kinematic Inertial Translatory Tripod Extremity Robot) as its foundation and produces Lunar core samples two meters long and fifty millimeters in diameter. The drill bit used for this is composed of 30 per carat diamonds in a sintered tungsten carbide matrix. To drill up to 50 m depths, the bit assembly will be attached to a drill string made from 2 m rods which will be carried in racks on SKITTER. Rotary power for drilling will be supplied by a Curvo-Synchronous motor. SKITTER is to support this system through a hexagonal shaped structure which will contain the drill motor and the power supply. A micro-coring drill will be used to remove a preliminary sample 5 mm in diameter and 20 mm long from the side of the core. This whole system is to be controlled from earth. This is carried out by a continuously monitoring PLC onboard the drill rig. A touch screen control console allows the operator on earth to monitor the progress of the operation and intervene if necessary.

Harvey, Jill↗

NASA NTRS2003

An Automated, Low Mass, Low Power Drill for Acquiring Subsurface Samples of Ground Ice for Astrobiology Studies on Earth and on Mars

As a project that is part of NASA s Astrobiology Technology & Instrument Development Program (ASTID), we are developing a low mass (approx.20kg) drill that will be operated without drilling fluids and at very low power levels (approx.60 watts electrical) to access and retrieve samples from permafrost regions of Earth and Mars. The drill, designed and built as a joint effort by NASA JSC and Baker-Hughes International, takes the form of a down-hole unit attached to a cable so that it can, in principle, be scaled easily to reach significant depths. A parallel laboratory effort is being carried out at UC Berkeley to characterize the physics of dry drilling under martian conditions of pressure, temperature and atmospheric composition. Data from the UCB and JSC laboratory experiments are being used as input to a drill simulation program which is under development to provide autonomous control of the drill. The first Arctic field test of the unit is planned for May 2004. A field expedition to Eureka on Ellesmere Island in Spring 2003 provided an introduction for several team members to the practical aspects of drilling under Arctic conditions. The field effort was organized by Wayne Pollard of McGill University and Christopher McKay of NASA ARC. A conventional science drill provided by New Zealand colleagues was used to recover ground ice cores for analysis of their microbial content and also to develop techniques using tracers to track the depth of penetration of contamination from the core surface into the interior of the samples.

Briggs, G. A.↗

NASA NTRS2006

Self-propelled instrumented deep drilling system

An autonomous subsurface drilling device has spaced-apart forward and rearward feet sections coupled to an axial thruster mechanism between them to operate using an inchworm method of mobility. In one embodiment, forward and rearward drill sections are carried on forward and rearward feet sections for drilling into material in the borehole in both forward and rearward directions, to allow the device to maneuver in any direction underground. In another embodiment, a front drill section has a drill head for cutting into the borehole and conveying cuttings through a center spine tube to an on-board depository for the cuttings. The feet sections of the device employ a foot scroll drive unit to provide radial thrust and synchronous motion to the feet for gripping the borehole wall. The axial thrust mechanism has a tandem set of thrusters in which the second thruster is used to provide the thrust needed for drilling, but not walking. A steering mechanism composed of concentric inner and outer eccentric rings provided with the rearward feet section allow small corrections in both direction and magnitude to the drilling direction as drilling commences.

Myrick, Thomas M.↗

NASA NTRS2018

Auto-Gopher-2 – An Autonomous Wireline Rotary Piezo-Percussive Deep Drilling Mechanism

Drilling deep into the subsurface of planetary bodies in the Solar System for samples acquisition enables critical capabilities for future NASA exploration missions in its quest to understand the origins of the Solar System and potentially the search for life. Such planetary bodies as Mars and Europa are key targets for potential missions that would require reaching great depths. Performing drilling while using minimal mass/volume systems and with low energy consumption are the main requirements that are imposed on such technologies. A wireline deep drill, called Auto-Gopher-2, is currently being developed as a joint effort between JPL and Honeybee Robotics Ltd. The Auto-Gopher II is a wireline rotary piezo-percussive deep drilling mechanism that combines formation breaking by rotating and piezoelectric actuator hammering and cuttings removal by rotating a fluted bit. The hammering mechanism is based on the Ultrasonic/Sonic Drill/Corer (USDC) mechanism that has been developed as an adaptable tool for many drilling and coring applications. The USDC uses an intermediate ball-shape free-mass to transform high frequency vibrations of a piezoelectric transducer horn tip into sonic hammering of the drill bit. The lessons learned from the previous studies are being implemented into the development of the Auto-Gopher-II, an autonomous deep wireline drill with integrated cuttings and sample management and drive electronics. Subsystems of the wireline drill are being developed in parallel at JPL and Honeybee Robotics, Ltd. Issues related to the bit and its ability to retain the cuttings for caching and removal are currently being addressed. This paper presents the development efforts of the piezoelectric actuator, cuttings removal and retention flutes and drive electronics.

Bar-Cohen, Yoseph↗

NASA NTRS1974

Rock melting technology and geothermal drilling

National awareness of the potential future shortages in energy resources has heightened interest in exploration and utilization of a variety of geothermal energy (GTE) reservoirs. The status of conventional drilling of GTE wells is reviewed briefly and problem areas which lead to higher drilling costs are identified and R and D directions toward solution are suggested. In the immediate future, an expanded program of drilling in GTE formations can benefit from improvements in drilling equipment and technology normally associated with oil or gas wells. Over a longer time period, the new rock-melting drill bits being developed as a part of the Los Alamos Scientific Laboratory's Subterrene Program offer new solutions to a number of problems which frequently hamper GTE drilling, including the most basic problem - high temperature. Two of the most favorable characteristics of rock-melting penetrators are their ability to operate effectively in hot rock and produce glass linings around the hole as an integral part of the drilling process. The technical advantages to be gained by use of rock-melting penetrators are discussed in relation to the basic needs for GTE wells.

Rowley, J. C.↗