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.

Copyright © 2006 by American Society of Mechanical Engineers
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Figure 1

Illustration of stages in the friction drilling process

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Figure 2

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

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Figure 3

Key dimensions of the friction drilling tool

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Figure 4

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

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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

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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

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Figure 7

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

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Figure 8

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

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Figure 9

Comparison between the experimental and thermal modeling temperature

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Figure 10

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

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Figure 11

A band of discoloration in the drilled hole

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Figure 12

Six stages in friction drilling force modeling

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Figure 13

Geometrical relationship to calculate h*

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Figure 14

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



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