Experimental and Numerical Analysis of the Friction Drilling Process

Journal Article · Sun Jan 01 04:00:00 EST 2006 · Journal of Manufacturing Science and Engineering

DOI:https://doi.org/10.1115/1.2193554· OSTI ID:1003656

Miller, Scott F ^[1]; Li, Rui ^[1]; Wang, Hsin ^[1]; McSpadden, Jr, Samuel Boyce ^[1]; Shih, Albert J. ^[2]

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1. ORNL
2. University of Michigan

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.

• Research Organization: Oak Ridge National Laboratory (ORNL); High Temperature Materials Laboratory
• Sponsoring Organization: EE USDOE - Office of Energy Efficiency and Renewable Energy (EE)
• DOE Contract Number: AC05-00OR22725
• OSTI ID: 1003656
• Journal Information: Journal of Manufacturing Science and Engineering, Journal Name: Journal of Manufacturing Science and Engineering Journal Issue: 3 Vol. ASME 128; ISSN 1087-1357
• Country of Publication: United States
• Language: English

Related Subjects

36 MATERIALS SCIENCE
DRILLING
FRICTION
MATHEMATICAL MODELS
MECHANICS
METALS
NUMERICAL ANALYSIS
ROTARY DRILLS
SHEETS
TEMPERATURE MEASUREMENT
THERMODYNAMICS