Abstract
Friction drilling allows the formation of holes in the thin sheet metal without material removal. In this process, no chip outburst occurs, the material of the hole is displaced in a doughy state by a conical thorn forming bush. Large deformation of workpiece material and shooting of both the tool and workpiece temperatures are high in the process of friction drilling. Hence, modeling and simulation of the process becomes essential to predict the material flow, and temperature distribution, which are difficult to measure experimentally during friction drilling. The objective of this work is to numerically analyze the quality of bush formation in the thin sheet metal of copper (Cu2C) and to predict the temperature distribution, thrust force, and torque in the workpiece. Validation shows high degree of closeness and agreement between the numerical results and experimental results
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