Experimental and Numerical Analysis of the Friction Drilling Process

2006 ◽  
Vol 128 (3) ◽  
pp. 802-810 ◽  
Author(s):  
Scott F. Miller ◽  
Rui Li ◽  
Hsin Wang ◽  
Albert J. Shih
Keyword(s):  
Thrust Force ◽  
Infrared Camera ◽  
Element Model ◽  
Single Step ◽  
Threshold Temperature ◽  
Force Model ◽  
Drilling Process ◽  
Measured Temperature ◽  
Friction Drilling ◽  
Hole Making

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.

scholarly journals A Force Sensorless Method for CFRP/Ti Stack Interface Detection during Robotic Orbital Drilling Operations

2015 ◽  
Vol 2015 ◽  
pp. 1-11 ◽  
Author(s):  
Qiang Fang ◽  
Ze-Min Pan ◽  
Bing Han ◽  
Shao-Hua Fei ◽  
Guan-Hua Xu ◽  
...  
Keyword(s):  
Cutting Force ◽  
Thrust Force ◽  
Cutting Parameters ◽  
Force Model ◽  
Drilling Process ◽  
Reinforced Plastics ◽  
Orbital Drilling ◽  
Drilling Parameters ◽  
Drilling Operations ◽  
Machining Properties

Drilling carbon fiber reinforced plastics and titanium (CFRP/Ti) stacks is one of the most important activities in aircraft assembly. It is favorable to use different drilling parameters for each layer due to their dissimilar machining properties. However, large aircraft parts with changing profiles lead to variation of thickness along the profiles, which makes it challenging to adapt the cutting parameters for different materials being drilled. This paper proposes a force sensorless method based on cutting force observer for monitoring the thrust force and identifying the drilling material during the drilling process. The cutting force observer, which is the combination of an adaptive disturbance observer and friction force model, is used to estimate the thrust force. An in-process algorithm is developed to monitor the variation of the thrust force for detecting the stack interface between the CFRP and titanium materials. Robotic orbital drilling experiments have been conducted on CFRP/Ti stacks. The estimate error of the cutting force observer was less than 13%, and the stack interface was detected in 0.25 s (or 0.05 mm) before or after the tool transited it. The results show that the proposed method can successfully detect the CFRP/Ti stack interface for the cutting parameters adaptation.

Experimental Study on Orbital Drilling Force and Machining Quality of CFRP

2014 ◽  
Vol 1061-1062 ◽  
pp. 542-549
Author(s):  
Xue Mei Chen ◽  
Qing Liang Chen ◽  
Feng Tao He ◽  
Xi Feng Fan
Keyword(s):  
Thrust Force ◽  
Orthogonal Experiment ◽  
Cutting Parameters ◽  
Force Model ◽  
Drilling Process ◽  
Drilling Force ◽  
Drilling Tool ◽  
Orbital Drilling ◽  
Reinforced Plastic ◽  
Predominant Factor

This paper aims to investigate orbital drilling process in carbon-fiber reinforced plastic (CFRP) composites with multi-point orbital drilling tool based on the robot automatic drilling system. One orthogonal experiment has been carried out, and the cutting forces of different parameters were measured online by dynamometer. Furthermore, the cutting force model was established through regression analysis, and the impacts of cutting parameters on thrust force were deeply analyzed. In addition, delamination and tear defects were inspected respectively, and the relationship between thrust force and delamination and tear was discussed. Our results indicate that thrust force increased with the increasing feed rate and axial feed depth, while decreased with the increasing spindle speed. Axial feed depth was found as the predominant factor on thrust force and defects. At last, the cutting parameters was optimized and then thrust force decreased more than 26% with almost none tear and burr around the hole, which indicates a better machine quality.

scholarly journals An Experimental Study on Copper Plates Using Friction Drilling.

2021 ◽  
Vol 9 (10) ◽  
pp. 767-770
Author(s):  
Samadhan Suresh Mule
Keyword(s):  
Feed Rate ◽  
Thrust Force ◽  
Spindle Speed ◽  
Resistance Force ◽  
Process Conditions ◽  
Work Material ◽  
Friction Drilling ◽  
Hole Making ◽  
Thin Walled ◽  
Conical Tool

Abstract: Friction drilling is a novel hole-making method that can be performed on thin-walled sheets. In recent years of study, the thrust force and torque under numerous process conditions were performed to demonstrate the benefits. In recent years of study, the thrust force and torque under various process conditions were performed to demonstrate the benefits. Our objective is to review the behavior of the material with the use of friction drilling by variation of thickness, Spindle speed, and feed rate. Our objective is to study the behavior of the material with the use of friction drilling by variation of thickness, Spindle speed, and feed rate. The friction between a rapid rotating conical tool and a sheet metal workpiece generates heat to soften and displace the metal to form a whole. Friction drilling is a non-traditional hole-making process in which a conical rotating tool is applied to penetrate the workpiece and make the outlet in a single step, without generating chips. the process relies on the heat generated thanks to the resistance force between tool and workpiece, to soften, penetrate and deform the work material into a bushing shape. Generally, friction drilling is applied to thin-walled materials owing to increasing connection length and clamping strength. The generated resistance heat cause softening piece of work material, increase its ductility, and providing it to flow, that extruded onto both the front and back sides of the holes. Keywords: Friction Drilling, Conical Tool, Material Displace, Temperature, Hardness & Thickness.

scholarly journals Thermo-Mechanical and Delamination Properties in Drilling GFRP Composites by Various Drill Angles

Polymers ◽  
2021 ◽  
Vol 13 (11) ◽  
pp. 1884
Author(s):  
Usama A. Khashaba ◽  
Mohamed S. Abd-Elwahed ◽  
Mohamed A. Eltaher ◽  
Ismail Najjar ◽  
Ammar Melaibari ◽  
...  
Keyword(s):  
Thrust Force ◽  
Infrared Camera ◽  
Heat Affect Zone ◽  
Measured Temperature ◽  
Machining Parameters ◽  
Cnc Machine ◽  
Dry Cutting ◽  
Specimen Holder ◽  
Drill Point ◽  
Speed Effect

This manuscript aims to study the effects of drilling factors on the thermal-mechanical properties and delamination experimentally during the drilling of glass fiber reinforced polymer (GFRP). Drilling studies were carried out using a CNC machine under dry cutting conditions by 6 mm diameter with different point angles of ∅ = 100°, 118°, and 140°. The drill spindle speed (400, 800, 1600 rpm), feed (0.025, 0.05, 0.1, 0.2 mm/r), and sample thickness (2.6, 5.3, and 7.7 mm) are considered in the analysis. Heat affected zone (HAZ) generated by drilling was measured using a thermal infrared camera and two K-thermocouples installed in the internal coolant holes of the drill. Therefore, two setups were used; the first is with a rotating drill and fixed specimen holder, and the second is with a rotating holder and fixed drill bit. To measure thrust force/torque through drilling, the Kistler dynamometer model 9272 was utilized. Pull-in and push-out delamination were evaluated based on the image analyzed by an AutoCAD technique. The regression models and multivariable regression analysis were developed to find relations between the drilling factors and responses. The results illustrate the significant relations between drilling factors and drilling responses such as thrust force, delamination, and heat affect zone. It was observed that the thrust force is more inspired by feed; however, the speed effect is more trivial and marginal on the thrust force. All machining parameters have a significant effect on the measured temperature, and the largest contribution is of the laminate thickness (33.14%), followed by speed and feed (29.00% and 15.10%, respectively), ended by the lowest contribution of the drill point angle (11.85%).

Friction Drilling: A Chipless Hole-Making Process

2006 ◽  
Author(s):  
Scott F. Miller ◽  
Albert J. Shih
Keyword(s):  
Finite Element ◽  
Cross Section ◽  
Thrust Force ◽  
Indentation Hardness ◽  
Production Environment ◽  
Drilling Tool ◽  
Metallurgical Analysis ◽  
Friction Drilling ◽  
Hole Making ◽  
Conical Tool

This paper summarizes the research on friction drilling, a chipless hole making process using the rotating conical tool. Extensive research in experiment, modeling, tool wear, and metallurgical analysis of friction drilling tool and workpiece has been carried out to demonstrate the feasibility of this technology for hole-making in thin metals. The experimentally measured thrust force and torque were analyzed and compared with analytical and finite element modeling results for validation. The microstructures and indentation hardness were characterized on the cross-section of friction drilled holes for different work-materials. For brittle cast metals, effects of workpiece temperature, spindle speed, and feed rate were analyzed. The wear of a tool, which is made of hard carbide material, for friction drilling of carbon steel workpiece, was also studied to demonstrate the capability of a durable tool in the production environment.

Thermo-Mechanical Finite Element Modeling of the Friction Drilling Process

2007 ◽  
Vol 129 (3) ◽  
pp. 531-538 ◽  
Author(s):  
Scott F. Miller ◽  
Albert J. Shih
Keyword(s):  
Finite Element ◽  
Plastic Strain ◽  
Finite Element Modeling ◽  
Thrust Force ◽  
Drilling Process ◽  
Mass Scaling ◽  
Element Modeling ◽  
Material Deformation ◽  
Work Material ◽  
Friction Drilling

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.

Investigation on thrust force in rotary ultrasonic drilling of CFRP/aluminum stacks

2019 ◽  
Vol 234 (2) ◽  
pp. 394-404
Author(s):  
Song Dong ◽  
Wenhe Liao ◽  
Kan Zheng ◽  
Wenrui Ma
Keyword(s):  
Theoretical Model ◽  
Thrust Force ◽  
Chip Thickness ◽  
Machining Process ◽  
Aviation Industry ◽  
Force Model ◽  
Drilling Process ◽  
Ultrasonic Drilling ◽  
Thrust Forces ◽  
Rotary Ultrasonic Drilling

The stacks of carbon fiber-reinforced polymer (CFRP) and aluminum are widely used in aviation industry due to its excellent mechanical and physical properties. Recently, rotary ultrasonic drilling technology which is recognized as a useful machining method has been introduced to machining these stacks. Thrust force influences the machinability directly such as tool wear, cutting temperature, and hole qualities. In this study, a theoretical model of thrust force for rotary ultrasonic drilling of CFRP/aluminum stacks is proposed. Based on the analysis of kinematic characteristics, the axial uncut chip thickness of rotary ultrasonic drilling is presented. Then the whole machining process of stacks is divided into five different states. Forces on cutting edge and chisel edge in different materials are modeled, respectively. After that, the thrust forces of five-state rotary ultrasonic drilling process are achieved by integrating with integral limits analysis in each state. Finally, verification experiments are conducted, and experimental results show that the trends of thrust forces agree well with the thrust force model. Therefore, this theoretical model can be used to evaluate the thrust force in rotary ultrasonic drilling of CFRP/aluminum stacks.

Three-dimensional finite element model of friction drilling process in hot forming processes

2015 ◽  
Vol 231 (3) ◽  
pp. 548-554 ◽  
Author(s):  
Mehmet Burak Bilgin ◽  
Kadir Gök ◽  
Arif Gök
Keyword(s):  
Finite Element ◽  
Axial Force ◽  
Three Dimensional ◽  
Element Model ◽  
Spindle Speed ◽  
Hot Forming ◽  
Drilling Process ◽  
Dimensional Finite Element ◽  
Friction Drilling ◽  
Three Dimensional Finite Element

Friction drilling processes are used commonly in hot forming operations. This process is similar to drilling processes but without using chip. This process is used especially for joining thin-walled metal components. In this study, the drilling process using centerdrill is investigated both experimentally and numerically. The finite element analyses (FEA) were conducted using deform-3D software based on finite element method (FEM). In this study, an analytic model is developed, which calculate the process parameters as torque and axial power, heat transfer coefficient. A comparison was also made for temperature, torque and axial force obtained from experimental and numerical analyses. At the end of the study, while the torque and axial force values decrease with increasing of spindle speed, temperature values of centerdrill and workpiece increase with increasing of spindle speed. A good consistency between both experimental and FEA simulations was found during the centerdrill process.

Effect of Friction Drilling on Metallurgical and Mechanical Properties of Composite Materials: A review

2020 ◽  
Vol 13 ◽  
Author(s):  
Mathew Alphonse ◽  
Bupesh Raja V.K ◽  
Palanikumar K.
Keyword(s):  
Mechanical Properties ◽  
High Speed ◽  
High Speed Steel ◽  
Single Step ◽  
Work Piece ◽  
Drilling Process ◽  
Drilling Tool ◽  
Sheet Metal Parts ◽  
Friction Drilling ◽  
Aisi H13

Abstract:: The objective of this study is to carry out a literature review on the effect of friction drilling parameters on the mechanical and metallurgical properties of materials. The friction drilling process uses heat generated by friction in between work piece and tool. In a single step tool penetrates into work material forming a circular hole and forms bushing without generating chips. Bushing acts as structural scaffold and guide to assemble sheet metal parts without need for separate threaded parts. This review focus on the basics of friction drilling, advantages, applications, metallurgical and mechanical properties of the tool and materials. Tools reviewed in this research are High speed steel (HSS) and AISI H13 chromium hot work steel. The study observes that coated friction drilling tool life is better than uncoated friction drilling tool. At higher spindle speed and feed rate good quality hole is produced with maximum bushing height and better surface finish.

scholarly journals Three-dimensional finite element model of the drilling process used for fixation of Salter–Harris type-3 fractures by using a K-wire

2015 ◽  
Vol 6 (2) ◽  
pp. 147-154 ◽  
Author(s):  
A. Gok ◽  
K. Gok ◽  
M. B. Bilgin
Keyword(s):  
Finite Element ◽  
Cutting Force ◽  
Thrust Force ◽  
Experimental Studies ◽  
Element Model ◽  
Drilling Process ◽  
Wire Temperature ◽  
Bone Model ◽  
Salter Harris ◽  
Model Temperature

Abstract. In this study, the drilling process was performed with Kirschner wire (K-wire) for stabilization after reduction of Salter–Harris (SH) type-3 epiphyseal fractures of distal femur. The study was investigated both experimentally and numerically. The numerical analyses were performed with finite element method (FEM), using DEFORM-3D software. Some conditions such as friction, material model and load and boundary must be identified exactly while using FEM. At the same time, an analytic model and software were developed, which calculate the process parameters such as drilling power and thrust power, heat transfer coefficients and friction coefficient between tool–chip interface in order to identify the temperature distributions occurring in the K-wire and bone model (Keklikoǧlu Plastik San.) material during the drilling process. Experimental results and analysis results have been found as consistent with each other. The main cutting force, thrust force, bone model temperature and K-wire temperature were measured as 80° N, 120° N, 69 °C and 61 °C for 400 rpm in experimental studies. The main cutting force, thrust force, bone model temperature and K-wire temperature were measured as 65° N, 87° N, 91 °C and 82 °C for 800 rpm in experimental studies. The main cutting force, thrust force, bone model temperature and K-wire temperature were measured as 85° N, 127° N, 72 °C and 67 °C for 400 rpm in analysis studies. The main cutting force, thrust force, bone model temperature and K-wire temperature were measured as 69° N, 98° N, 83 °C and 76 °C for 800 rpm in analysis studies. A good consistency was obtained between experimental results and finite element analysis (FEA) results. This proved the validity of the software and finite element model. Thus, this model can be used reliably in such drilling processes.

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