This work investigates the finite element modeling fem of large plastic strain and hightemperature workmaterial deformation in friction drilling. Friction drilling allows the formation of holes in the thin sheet metal without material removal. Dull drill, drills used with the incorrect parameters fail prematurely. Microstructural alterations associated with friction drilling of steel, aluminum, and titanium scott f. Advantages of coldform tapping in conjunction with friction drilling, over thread cutting are. Particularly when drilling erd wells the drag chart in combination with other drilling data can be used to asses the hole cleaning quality. Founded in 1980 in the netherlands, our company manufactures tungsten carbide flowdrills by in. Drilling holes in many materials using a centerdrill tool is a productive process to create stong connections. Differential pressure pipe sticking and mechanical pipe sticking are addressed in this section. Thrust force and torque in friction drilling of aisi 1020 carbon steel sheet. The purpose of this unconventional hole production method is. The process involves the highpressure injection of fracking fluid primarily water, containing sand or other proppants suspended with the aid of thickening agents into a wellbore. Pdf an experimental study on friction drilling of st12 steel. This drilling process makes holes in the metals by using friction to heat the surface.
This form drilling is a process of making a holes on the sheet metals by using heat generated in friction between the hole surface and tool. Friction drilling is a holeproduction method, in which the material is not cut by the tool. No special machines or additional components are needed 2 so that it is cost effective and small investment process. Friction drilling friction or form drilling fd process 15 is a nonconventional process to make holes on metal sheets. Friction factor operational issues could be flagged in the planning phase if friction factors used for torque and. An experimental investigation of hole geometry in friction. The horizontal directional drilling process the tools and techniques used in the horizontal directional drilling hdd process are an outgrowth of the oil well drilling industry. Materials that affect the drilling process are as follows and as shown in the fishbone diagram of fig. The main purpose of this research is to study the optimal process parameters for thermal friction drilling process on aisi 304 stainless steel. Flow drilling makes use of a highly heatresistant hard metal pointed object. Friction drilling is a nontraditional hole drilling method that owing to a beneficial of the heat which generated as a result of friction between a rotating. During drilling, the effects of machining parameters on the thrust force and the hole zone temperature were investigated. Drilling holes in many materials using a formdrill tool is a productive process to create strong threaded connections.
It was confirmed that the distribution of stress and temperature demonstrate the phenomenon of friction heat and. The heat generated from friction between a rotating conical tool and theworkpiece is used to soften the workmaterial and penetrate a hole. The process includes imposing friction and pressure on the target area. Optimization of thermal friction drilling using grey. The friction drilling process will analyze and simulated using ansys.
Typical setup of friction drilling has a work piece held rigidly on top of a piezo electric drilling dynamometer. A rotating conical tool is applied to penetrate a hole and create a bushing in a single step without generating chips. Work material is subjected to the large deformation and high temperature during the friction drilling process which causes alteration in macrostructure and material properties, these findings have been reported by miller s. Friction drilling is a fast and clean process which provides strong and high quality joints in less production steps. Effect of prehole diameter on bushing dimensions for. The numerical results indicated that high stress occurs at the tool contact surface and adjacent region in the primary penetration.
Friction drilling is a method of making holes in metal in which the material is pushed out of the way with the aid of heat from friction. In this process a rotating conical tool makes a hole into the work piece without generating any chip. The main purpose of this research is to study the optimal machining parameters for a novel process of thermal friction drilling on sus 304 stainless steel. Analysis of the friction drilling process friction drilling is a nontraditional holemaking process. Friction drilling, form tapping and rotary broaching for. Experimental analysis and numerical modeling of the friction drilling process.
Identification of drilling parameters during the flow. Experimental investigations and multiobjective optimization of. Friction drilling, also known as thermal drilling, flow drilling, form drilling, or friction stir drilling, is a nontraditional hole making method. Shih submitted may 26, 2005 friction drilling, also called thermal drilling, is a novel sheet metal holemaking process.
Increased pull out strength of the formed thread as the process reforms the material in the bush, without cutting into the natural grain structure. The process involves forcing a rotating, pointed tool through a sheet metal workpiece. The friction drilling process relies on the heat generated from the frictional force between the tool and sheet metal workpiece to soften, penetrate, and deform the. The rising temperature causes the sample to soften. Basically, the drill bit pushes the material in its way by producing heat through friction. The anova, taguchis technique is implemented to explore the effect of the process parameters and analyze the form drilling variables such as feed, speed, thickness of material, dia of tool. Thermomechanical finite element modeling of the friction. Friction stir drilling is also called as flow drill, thermal drill, and form drill. Flow drilling friction drilling form drilling youtube. Friction is used to produce a bushing that can be tapped afterwards. Figure 2, shows the different stages of the friction drilling process. In this study, aisi 1010 steel squaretube materials were drilled on a computer numerical control cnc machine center by friction drilling.
In fsw, a rotating tool is used to generate frictional heat and stir the work material around the tool to join two parts. Called friction drilling, form drilling, flow drilling or thermal drilling, the process uses a conical bit, spun at high speeds and applied with high pressure, that relies on friction itself to bore through the material. The experiments were conducted according to an l9 orthogonal array based on taguchi experimental designs method, and the multiple performance characteristics correlated with surface roughness sr and bush length bl was investigated by. Friction between the wall of the hole and the drill string vanishes becomes zero during the rotation of the drill.
Friction drilling experimental are generally carried out by using a three axis computer numerical controlled vertical machining center. The use of drilling rigs of an appropriate capacity is required. In this process, no chip outburst occurs, the material of the hole is. Numerical simulation and analysis of friction drilling. In which hss, tungsten tools are machined the a7075t6 alumina work piece. Flow drilling is a noncutting method for drilling holes into metal, in which the material is melted by adding high pressure and frictional energy flow tapping is also a noncutting method. Founded in 1980 in the netherlands, our company manufactures tungsten carbide flowdrills by inhouse production. Coefficients of friction between the drill string and drill hole with unknown cuttings bed packing, which are often called friction factors, have been reported in the range of 0. During drilling, the friction between a rotating tool and the sheet metal workpiece generates significant.
Thermal friction drilling is a novel nontraditional holemaking process. Numerical simulation on friction drilling of aluminum. Today we will learn about friction welding principle, working, types, application, advantages and disadvantages with its diagram. Friction drilling in metals of very less thickness and the properties of the friction. Characteristics of tools used in the friction drilling method. Friction drilling is more suitable for ductile materials, but it can be used with composites. An experimental study has been carried out by varying process parameters rotational speed, drilling force, coating and geometry of the screw. Experimental analysis and numerical modeling of the friction. The friction drilling process was experimentally conducted using a drilling tool without flutes. The tool is often made of tungsten carbide and rotates at high speed, which produces friction heat. The tungsten carbide is a suitable tool for the fiction drilling process 1012. Experimental investigation of friction drilling on brass.
Friction drilling is the simplest way to make holes in any kind of metals. The novel thermal friction drilling process needs a further and comprehensive study to understand the effects of drilling performance on stainless steels 7. As a result, an increase of rotational speed and drilling force allows significant reduction in drilling time and introduce an important variation of the torque installation. Solid state welding are those welding process in which no external heat is. Hydraulic fracturing also called fracking, fracing, hydrofracking, fraccing, fracing, and hydrofracturing is a well stimulation technique involving the fracturing of bedrock formations by a pressurized liquid. The process is also named as friction drilling, flow drilling, thermomechanical drilling, friction stir drilling, flow drilling, thermal friction drilling and form drilling. Tool case with all the necessary tools to start flowdrilling. The deformation and equivalent vonmises stress, maximum elastic strain of. Also know as flow drill process, frictiondrill process. In industrial terms, it is well known as flow drilling or thermal drilling. It is an alternative process, compared to conventional drilling.
The bushing increases depth for threading and the clamp load. In this paper authors have investigated the effect of friction drilling input. In friction drilling, the tungsten carbide tools with different friction angle and diameters were used. The fig 1 shows the difference stages of friction drilling process, for making hole. It is based on the material flow, by using the heat caused by the friction of a conical shape rotary tool without cutting edges.
By hot forming with friction enery, a hole is created and the wall thickness is. Experimental and numerical analysis of the friction drilling process. Cross sectional view of deformation of the workpiece in friction drilling at. Investigate the surface roughness and bushing shape in. The components of a horizontal drilling rig used for. Specifically designed for drilling in aluminium with a 120 degree counter sink. Pdf experimental analysis and numerical modeling of the.
Friction drilling, a non traditional hole making process is performed on brass, aluminium and stainless steel using a conical tungsten carbide tool. Microstructural alterations associated with friction. The thrust forces involved in the process of friction drilling for various speeds and feed rates is measured with the help of drill tool dynamometer. Friction drilling is a chipless hole making process. In this primarily, the drill bit penetrates into the. An alternative metal drilling process uses a bit that doesnt have a cutting edge at all. If you have ever struggled with a spinning nutsert or welded on a pipe bung to a thin exhaust pipe, you wont believe how much easier this process can be. It is a novel method using the principle of hot forming. Referred to thermal friction drilling, there are recently few related research works.
Over the last thirtyfive years, thousands of customers in more than fifty countries, changed over to the friction drill technology. Due to the possible collapse of subsoil during drilling, the forming process usually required temporary protection by the use of steel casings or some kind of drilling fluid such as bentonite slurry. Flowdrill thermal friction drilling kits make drilling and tapping holes in thin metals fast, accurate and inexpensive. One can easily judge the application of friction drilling by its name. The process forms a bushing in situ and is clean and chipless. In this manufacturing process, a sample material is heated up by the effect of friction, generated between the rotating conical tool and the drilled material. A rotating conical tool is applied to penetrate a hole and create a bushing in a single step without generating. The process involves penetrate a rotating conical tool through a sheet metal work piece. The friction will produce enough heat and pressure will push the bit and make a hole. Laminate material drill bits drill bit rings entry material backup material tooling pins 24. Optimization of thermal friction drilling process based on. Friction drilling process is a rotating conical tool to penetrate the work piece 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. Friction factors oil well drilling netwas group oil. Keywords friction drilling, surface roughness, bushing height, bushing sheet thickness. Flowtap compliments the friction drilling process to increase the depth of threads formed in thin metal. Friction drilling process is a circular hole making process by friction principle. Here the hole is created by soften the work piece material by the heat energy generated by the frictional force due to axial and rotational forces between the. Friction drilling is a nontraditional holemaking process. During drilling operations, a pipe is considered stuck if it cannot be freed and pulled out of the hole without damaging the pipe and without exceeding the drilling rig s maximum allowed hook load. Optimization and thermal analysis of friction drilling on. Various properties of the friction drilling tool namely strength, rotational stiffness and moment capacity of the friction drill tool for drilling of steel specimens are referred.
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