FINAL REPORT HARD ROCK DRILLING

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP78-03645A000200090001-6
• Release Decision: RIPPUB
• Original Classification: S
• Document Page Count: 13
• Document Creation Date: December 22, 2016
• Document Release Date: May 9, 2011
• Sequence Number: 1
• Publication Date: February 8, 1957
• Content Type: REPORT

f
i
Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
~lJ'1~ ~`' ~ 5'~ 'j ~" ` t
y ,~ ~~
i
RESEARCH ORDER N0. 6
_.. _ _ -
~ ---
i
COPY NO..~_ OF~_COPIES
Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
J0~ NQ, ~~~~-_~
FaL~'~R N0. __ 7am~~A~
TOT~;~. D~~CS HE~~~~~ ~.
25X1
 - -- --- ~-__1 - -11. - --
Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
StC:Kt. I
REPORT N0.
33 5
8 FEBRUARY 1957
FINAL REPORT
HARD ROCK DRILLING
PRE PARED FO R
METAL PRODUCTS RESEARCH ASSOCIATES
RESEARCH ORDER N0.6
PREPARED BY
CCr`~CT
Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
 i ~ _
Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
JCI.KC f
FRONTISPIEC E
Figure 1.
Figure 2.
SECRET
Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
 i -~ - _- --
Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
sECKt ~
HARD ROCK DRILLING
TABLE OF CONTENTS
FRONTISPIECE
I
INTRODUCTION
II
PRELIMINARY CONSIDERATIONS
III
DESIGN CRITERIA
IV
DETAIL DESIGN
V
CONCLUSION
G. O. Noville Drawing No. 289 - 001
SECRET'
PAGE L
Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
 Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
PAGE Z
HARD ROCK DRILLING
I INTRODUCTION
This report presents to the Metal Products Research
Associates a technical report describing the development of compon-
ents usable for penetrating and providing openings in thick masonry
walls. This report presents the results obtained in the performance
of Research Order No. 6 issued under Contract RD - ??.
CC~`D CT
Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
 Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
JtC.~Kt f
Pace 2
HARD ROCK DRILLING
PRELIMINARY CONSIDERATIONS
New equipment and techniques have inspired new concepts in
engineering design of hard rock drilling and penetration methods. These
new techniques have arisen from the use of new drill materials such as
the various cemented carbides. Cemented carbide tipped tools have made
possible high speed drilling without regard to heating and dulling of the drill
point. This has required new concepts of power drives to match the speed
and feed capacity of such drills. Thus, the program conducted by the con-
tractor has been concentrated on the development of a drill motor rather
than drill bits.
Based upon data furnished to the contractor by the project engineer, it
was determined that the output speed of the drill motor should be variable
between 2800 rpm and 800 rpm. It was further specified that the power re-
quirements should be supplied directly by human effort. This latter require-
ment eliminated the consideration of electric motors powered by batteries
or by a manually operated generator. Spring driven units were removed
from consideration because of the limited length of time during which this
type of unit could supply power.
SECRET
Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
 Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
JCC,.KC f
PAOfi 3
HARD ROCK DRILLING
III DESIGN CRITERIA
With the foregoing considerations in mind, the contractor and
project engineer determined that a foot operated unit similar in configura-
tion to a bicycle type exerciser would offer the optimum configuration for
transforming the energy of a' man into power available for drilling. The
operator would sit upon a bicycle seat, grasp a handle bar, and rotate the
pedals by foot action. The rotating effort applied to the pedals would then
be transmitted by chain or belt drives to a four speed bicycle transmission,
and the output shaft of the transmission would be coupled to a flexible out-
put shaft. The output end of the flexible shaft would contain a chuck suitable
for holding the drill bit.
A review of data available showed that a man could operate the pedals
on a racing bicycle at an average speed of 100 rpm for a long period of
time. This data was obtained from bicycle speed and distance records indi-
cating an average speed of 21 mph for six to ten hours of road racing. It
has therefore been assumed that a maximum pedal speed of 116 rpm was
within reason for the duration of the drilling operations. The decision was
then made to use a Sturmey -Archer four-speed bicycle transmission, type
F W, and build the frame unit about it. This transmission provides the
maximum variation between high speed and low speed that was available
commercially. A chain drive from the pedal sprocket to the four-speed
C C~'D CT
Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
 Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
JC~.KC f
PAGE
HARD ROCK DRILLING
transmission provides the first stage of the drive,. and a Gilmer timing
belt drive from the transmission to a right angle gear unit provides the
last stage of the drive. The roller chain drive is satisfactory for the first
stage as the linear speed of the chain is relatively slow. However, a roller
chain drive on the last stage proved unsatisfactory from the standpoint of
noise level, but the timing belt drive is quite satisfactory.
Another consideration in the design of the drill unit was that it should
be capable of being packaged within a conventional suitcase. In order to
comply with this requirement the frame was designed so as to be easily
assembled and disassembled without the use of tools. Spring actuated de-
tents and pins are utilized in those joints which must be readily disassem-
bled, and the sprocket crank has been hinged to enable the pedals to be ro-
tated within the frame and thus be packaged in the suitcase.
CFC'RFT
Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
 Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
J C~.1'CC t
PAGE 5
HARD ROCK DRILLING
DETAIL DESIGN
The "bicycle" frame is primarily constructed of aluminum
tubing welded together by the heliarc process and is shown in the photo-
graphs, Figures 1 and 2, and assembly drawing, 289 - 001. Wherever
possible, standard bicycle parts have been used for such parts as the seat,
seat post, drive sprocket, sprocket crank, pedals, bearings, chain, and
four-speed transmission. The output shafts are standard flexible drive
units, Flexarm No. 521, manufactured by S. S. White Dental Manufacturing
Co. , equipped with their No. 5 Handpiece which is suitable for holding drills
up to and including 1/4 inch shank diameter.
The drive mechanism consists of a 1/2 inch pitch by 1/8 inch wide rol-
ler chain drive with a speed increase from a 52 tooth drive sprocket to a 14
tooth driven sprocket attached to a Sturmey -Archer type F W four-speed
transmission with a speed increase of 26.6, a 1: 1 .ratio, and speed re-
ductions of 21 ?,~ and 33 ?Jo, a 3/8 inch pitch by 1/2 inch wide Gilmer timing
belt drive with a speed increase from a 72 tooth drive pulley clamped to
the hub of the transmission to a 14 tooth driven pulley, and a 1: 1 right angle
gear unit with two output shafts at 90? to one another. Three S. S. White
Dental Manufacturing Co. flexible shafts, Flexarm No. 521, in lengths of
approximately 5 feet, 9 feet, and 12 feet were furnished with the drill unit.
These Flexarm assemblies were not complete fn themselves as only one
sEC_R F~
Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
 Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
JC~.1'CC t
PAGE ~/
HARD ROCK DRILLING
motor coupling and one handpiece were furnished for all three shafts. This
was done in the interest of reducing the weight of the completed package
and also of keeping the cost to a minimum. Two interchangeable chucks
have been provided to accept drill shanks up to 1/4 inch in diameter. The
flexible drive shaft assembly is rated at 1/4 horsepower at 1750 rpm which
is ample for the requirements of this program.
With a pedal speed of 116 rpm and with the top speed of the transmission
engaged, the output shaft will rotate at
52 x 72 x 1.266 x 116 = 2800 rpm
14 14 1
This pedal sprocket speed is well within the capabilities of a man, and the
output speed as calculated is the maximum required by the specifications.
With the same pedal sprocket speed, and with the transmission engaged in
the slowest output speed ratio, the output speed will be
52 x 72 x (1 - .33) x 116 = 1480 rpm
14 14 1
In order to obtain a drill speed of 800 rpm, it will be necessary to decrease
the pedal sprocket speed to 63 rpm and to engage slow speed stage of the
transmission.
SECRET
Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
 Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
~tC:Kt E
PAdE
HARD ROCK DRILLING
CONC LUSION
The prototype unit was delivered to the customer for evaluation.
Preliminary information has indicated that this unit operated satisfactorily.
However, the energy required to operate the drill through the desired mat-
erials over an extended period of time was beyond the output available from
a team of three men alternating as operators with each man pedalling for
one minute and resting for two minutes.
~FC'R F7
Sanitized Copy Approved for Release 2011/05/09 :CIA-RDP78-03645A000200090001-6
 Sanitized Copy Approved for Release 2011/05/09: CIA-RDP78-03645A000200090001-6
Sanitized Copy Approved for Release 2011/05/09: CIA-RDP78-03645A000200090001-6