Thermo-Mechanical Finite Element Modeling of the Friction Drilling Process

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

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

J. Manuf. Sci. Eng 129(3), 531-538 (Jan 03, 2007) (8 pages) doi:10.1115/1.2716719 History: Received July 10, 2006; Revised January 03, 2007

Friction drilling uses a rotating conical tool to penetrate the workpiece and create a bushing in a single step without generating chips. This research investigates the three-dimensional (3D) finite element modeling (FEM) of large plastic strain and high-temperature work-material deformation in friction drilling. The explicit FEM code with temperature-dependent mechanical and thermal properties, as well as the adaptive meshing, element deletion, and mass scaling three FEM techniques necessary to enable the convergence of solution, is applied. An inverse method to match the measured and modeling thrust force determines a coefficient of friction of 0.7 in this study. The model is validated by comparing the thrust force, torque, and temperature to experimental measurements with reasonable accuracy. The FEM results show that the peak temperature of the workpiece approaches the work-material solidus temperature. Distributions of plastic strain, temperature, stress, and deformation demonstrate the thermomechanical behavior of the workpiece and advantages of 3D FEM to study of work-material deformation in friction drilling.

Copyright © 2007 by American Society of Mechanical Engineers
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Figure 1

Cross section of workpiece in experiment and modeling at four stages of tool location in friction drilling of 1.6mm thick Al 6061 at tool travel of (a) 0mm, (b) 2.77mm, (c) 7.19mm, and (d) 14.0mm from the initial contact (5.3mm hole diameter for scale)

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Figure 2

Depiction of deleted elements (dark) in finite element modeling of friction drilling

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Figure 3

Mesh, boundary condition, and tool geometry in friction drilling: (a) initial mesh and positions of the tool and workpiece, (b) close-up view of the mesh near the tool tip, (c) bottom view showing the stationary support plate, and (d) tool geometry and parameters

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Figure 4

Two thermocouples embedded in small holes 7.5mm from the center of drilling for temperature measurement (5.3mmdia drilled hole for scale)

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Figure 5

Comparison of modeling thrust force and torque for different friction coefficients (4.23mm∕s feed rate and 3000rpm spindle speed)

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Figure 6

Comparison of the experiment versus model predicted thrust force and torque in friction drilling for 0.7 coefficient of friction (3000rpm spindle speed and 5.93mm∕s, 4.23mm∕s, and 2.54mm∕s feed rates).

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Figure 7

Comparison of the tool-workpiece position at peak thrust force (a) FEM, 1.78mm, and (b) experiment, 2.75mm, tool travel from the initial tool-workpiece contact (4.23mm∕s tool feed rate)

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Figure 8

FEM modeling and experimental measurement of temperature in friction drilling, numbers represent distance from hole center (0.7 coefficient of friction, 3000rpm spindle speed, and 4.23mm∕s tool feed rate)

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Figure 9

Deformed mesh and distribution of plastic strain, temperature, and von Mises stress (4.23mm∕s feed rate, 3000rpm spindle speed, 0.7 coefficient of friction)

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Figure 10

Nodal velocity and force vectors at four tool locations



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