0
TECHNICAL PAPERS

Experimental and Numerical Analysis of the Friction Drilling Process

[+] Author and Article Information
Scott F. Miller, Rui Li, Albert J. Shih

Mechanical Engineering, University of Michigan, Ann Arbor, MI 48109

Hsin Wang

 Oak Ridge National Laboratory, Oak Ridge, TN 37831

J. Manuf. Sci. Eng 128(3), 802-810 (Jan 06, 2006) (9 pages) doi:10.1115/1.2193554 History: Received August 17, 2004; Revised January 06, 2006

Friction drilling is a nontraditional hole-making process. A rotating conical tool is applied to penetrate a hole and create a bushing in a single step without generating chips. Friction drilling relies on the heat generated from the frictional force between the tool and sheet metal workpiece to soften, penetrate, and deform the work-material into a bushing shape. The mechanical and thermal aspects of friction drilling are studied in this research. Under the constant tool feed rate, the experimentally measured thrust force and torque were analyzed. An infrared camera is applied to measure the temperature of the tool and workpiece. Two models are developed for friction drilling. One is the thermal finite element model to predict the distance of tool travel before the workpiece reaches the 250°C threshold temperature that is detectable by an infrared camera. Another is a force model to predict the thrust force and torque in friction drilling based on the measured temperature, material properties, and estimated area of contact. The results of this study are used to identify research needs and build the foundation for future friction drilling process optimization.

FIGURES IN THIS ARTICLE
<>
Copyright © 2006 by American Society of Mechanical Engineers
Your Session has timed out. Please sign back in to continue.

References

Figures

Grahic Jump Location
Figure 1

Illustration of stages in the friction drilling process

Grahic Jump Location
Figure 2

Experimental setup in friction drilling: (a) overview and (b) close-up view of the spinning tool contacting the workpiece

Grahic Jump Location
Figure 3

Key dimensions of the friction drilling tool

Grahic Jump Location
Figure 4

Thrust force and torque in friction drilling of AISI 1020 carbon steel sheet

Grahic Jump Location
Figure 5

Cross-sectional view of deformation of the workpiece in friction drilling at positions (a) A, (b) B, (c) C, and (d) D in Fig. 4

Grahic Jump Location
Figure 6

Infrared camera pictures of friction drilling: ( a) 2s, (b) 3s, (c) 5s, (d) 8.5s, (e) 10s, and (f) 12s from the contact of the tool and workpiece

Grahic Jump Location
Figure 7

Maximum workpiece temperature and the minimum temperature detectable by the infrared camera

Grahic Jump Location
Figure 8

The axisymmetric finite element mesh and the thermal model at three time steps

Grahic Jump Location
Figure 9

Comparison between the experimental and thermal modeling temperature

Grahic Jump Location
Figure 10

Two basic areas for contact between the tool and workpiece in friction drilling force modeling

Grahic Jump Location
Figure 11

A band of discoloration in the drilled hole

Grahic Jump Location
Figure 12

Six stages in friction drilling force modeling

Grahic Jump Location
Figure 13

Geometrical relationship to calculate h*

Grahic Jump Location
Figure 14

Comparison of the experiment versus model predicted thrust force and torque in friction drilling

Tables

Errata

Discussions

Some tools below are only available to our subscribers or users with an online account.

Related Content

Customize your page view by dragging and repositioning the boxes below.

Related Journal Articles
Related eBook Content
Topic Collections

Sorry! You do not have access to this content. For assistance or to subscribe, please contact us:

  • TELEPHONE: 1-800-843-2763 (Toll-free in the USA)
  • EMAIL: asmedigitalcollection@asme.org
Sign In