Abstract
In thermal friction drilling (TFD) operations, the geometrical dimensions of bushing shape, height and wall thickness are the most vital consequences, since these increase the connecting length and strength. In this paper, AA7075-T651 aluminum alloys with 2, 4, 6, 8, and 10 mm thicknesses were drilled with the TFD process in order to investigate density, volume ratio, and height and wall thickness of the bushings. The experiments were conducted at constant spindle speed and feed rate conditions by using High Speed Steel (HSS) conical tools of 5, 10, 15, and 20 mm in diameter. It was experimentally found that the bushing height and the wall thickness had a tendency to increase linearly with the increase in both material thickness and tool diameter. The effect of tool diameter was found to have more influence on the measurable values than the thickness of the drilled material. The density of the bushing changed trivially. Approximately 70–75 percent of the evacuated material formed the bushing shape in TFD operations.
Highlights
Friction drilling is a hole production method, in which the metal cast sheet materials are drilled without cutting since a material sample heats up with the effect of the friction in the area of the conical tool and material contact
These dimensions have been barely investigated in the open literature
This idea may be valid for thin sheet metal materials, thinner than 2 mm, but it does not seem to be valid for sheet materials thicker than 2 mm
Summary
Friction drilling is a hole production method, in which the metal cast sheet materials are drilled without cutting since a material sample heats up with the effect of the friction in the area of the conical tool and material contact. A decrease in bushing height leads to an increase in the wall thickness of the bushing formation, which provides a greater screwing area by connecting sheet materials [7,8,9,10]. Deformation and fracture of the drilled occurrence of petal formation and cracks on bushing selected tool Better geometry provides material cause the occurrence of petal formation and shape. Due to this riseto in temperature, that occurs occursbetween between tool—workpiece interface to the friction Due this rise in the material thermally softens, and the yielding decreasespoint to facilitate plastic deformation to temperature, the material thermally softens, andpoint the yielding decreases to facilitate plastic provide the bushing formation.
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