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Investigate the effect of tool conical angle on the bushing height, wall thickness and forming in friction drilling of A7075-T651 aluminum alloy

Year 2013, , 61 - 74, 01.06.2013
https://doi.org/10.12748/uujms/20131712

Abstract

Friction drilling process is a non-traditional hole drilling process formed by thermal friction having the most important features such as no pollution, short machining time and long tool life. In this process conical tool is used to generate heat by friction to soften and generate a thin workpiece and create a bushing without generating chips. In this friction drilling experimental study, the selected spindle speeds were 2400 rpm, 3600 rpm, and 4800 rpm, feed rates were 50 mm/min, 75 mm/min, and 100 mm/min and tool material was HSS tool with 24°, 36°, and 48° conical angles, 8 mm, 10 mm, and 12 mm cylindrical region diameters and 16 mm tool cylindrical region lengths. The specimens were A7075-T651 with thickness of 4 mm, and 6 mm. The effect of tool conical angle on the bushing height, bushing wall thickness, and bushing shape were analyzed. It was seen that for 4 mm and 6 mm materials thicknesses, according to the bushing height, the most optimum tool conical angle was 24° for all diameters. For 4 mm material thickness according to the bushing wall thickness 48° was the most optimum conical angle in friction drilling 8 mm diameter, 24° for friction drilling 10 mm and 12 mm diameters. The most optimum tool conical angle was 36° for 8 mm diameter, 24° for 10 mm and 12 mm diameters. With decreasing tool conical angle the bushing height was increased and bushing wall thickness was decreased. In the conditional low tool conical angles the softened material flow in the direction of tool motion in friction drilling, thus bushing height increased and wall thickness decreased. With increasing both tool conical angle and spindle speed the cracks in obtained bushing were advanced and the shape of bushing formed as petal. But with increasing feed rate the bushings shapes were not changed.

References

  • Miller SF, Tao J and Shih AJ. Friction drilling of cast metals. International Journal of Machine Tool and Manufacture, 2006; 46: 1526 – 1535.
  • Lee SM, Chow HM, Huang FY and Yan BH. Friction drilling of austenitic stainless steel by uncoated and PVD AlCrN – and TiAlN coated tungsten carbide tools. International Journal of Machine Tools and Manufacture, 2009; 49: 81 – 88. Lee SM, Chow HM and Yan BH. Friction drilling of IN – 713LC cast super alloy. Materials and Manufacturing Processes, 2007; 22: 893 – 897.
  • Krasauskas P. Experimental and statistical investigation of thermo-mechanical friction drilling process. Mechanika, 2011; 17(6): 681 – 686.
  • Miller SF, Blau P and Shih AJ. Microstructural alterations associated with friction drilling of steel, aluminium and titanium. Journal of Materials Engineering and Performance, 2005; 14 (5): 647 – 653.
  • Pantawane PD and Ahuja BB. Experimental investigations and multi-objective optimization of friction drilling process on AISI 1015. International Journal Of Applied Engineering Research, 2011; Dindigul 2(2): 448 – 461.
  • Chow MH, Lee MS and Yang LD. Machining characteristic study of friction drilling on AISI 304 stainless stell. Journal of Materials Processing Technology, 2008; 207: 180 – 186.
  • Miller SF, Blau PJ and Shih AJ. Tools wear in friction drilling. International journal of Machine Tools and Manufacture, 2007; 47: 1636 – 1645.
  • Miller SF, Wang H, Li R and Shih AJ. Experimental and numerical analysis of the friction drilling process. Journal of Manufacturing Science and Engineering, 2006; 128(3): 802 – 810.
  • Miller SF, Blau PJ and Shih AJ. Tools wear in friction drilling. International of Machine Tool and manufacture, 2007; 47: 1636 – 1645.
  • Dekkers G. Flow Drill Process Company Catalogs, Copyright by Flow Drill BV, Holland, 1993: 1 – 30.

Investigate the effect of tool conical angle on the bushing height, wall thickness and forming in friction drilling of A7075-T651 aluminum alloy

Year 2013, , 61 - 74, 01.06.2013
https://doi.org/10.12748/uujms/20131712

Abstract

Friction drilling process is a non-traditional hole drilling process formed by thermal friction having the most important features such as no pollution, short machining time and long tool life. In this process conical tool is used to generate heat by friction to soften and generate a thin workpiece and create a bushing without generating chips. In this friction drilling experimental study, the selected spindle speeds were 2400 rpm, 3600 rpm, and 4800 rpm, feed rates were 50 mm/min, 75 mm/min, and 100 mm/min and tool material was HSS tool with 24°, 36°, and 48° conical angles, 8 mm, 10 mm, and 12 mm cylindrical region diameters and 16 mm tool cylindrical region lengths. The specimens were A7075-T651 with thickness of 4 mm, and 6 mm. The effect of tool conical angle on the bushing height, bushing wall thickness, and bushing shape were analyzed. It was seen that for 4 mm and 6 mm materials thicknesses, according to the bushing height, the most optimum tool conical angle was 24° for all diameters. For 4 mm material thickness according to the bushing wall thickness 48° was the most optimum conical angle in friction drilling 8 mm diameter, 24° for friction drilling 10 mm and 12 mm diameters. The most optimum tool conical angle was 36° for 8 mm diameter, 24° for 10 mm and 12 mm diameters. With decreasing tool conical angle the bushing height was increased and bushing wall thickness was decreased. In the conditional low tool conical angles the softened material flow in the direction of tool motion in friction drilling, thus bushing height increased and wall thickness decreased. With increasing both tool conical angle and spindle speed the cracks in obtained bushing were advanced and the shape of bushing formed as petal. But with increasing feed rate the bushings shapes were not changed.

References

  • Miller SF, Tao J and Shih AJ. Friction drilling of cast metals. International Journal of Machine Tool and Manufacture, 2006; 46: 1526 – 1535.
  • Lee SM, Chow HM, Huang FY and Yan BH. Friction drilling of austenitic stainless steel by uncoated and PVD AlCrN – and TiAlN coated tungsten carbide tools. International Journal of Machine Tools and Manufacture, 2009; 49: 81 – 88. Lee SM, Chow HM and Yan BH. Friction drilling of IN – 713LC cast super alloy. Materials and Manufacturing Processes, 2007; 22: 893 – 897.
  • Krasauskas P. Experimental and statistical investigation of thermo-mechanical friction drilling process. Mechanika, 2011; 17(6): 681 – 686.
  • Miller SF, Blau P and Shih AJ. Microstructural alterations associated with friction drilling of steel, aluminium and titanium. Journal of Materials Engineering and Performance, 2005; 14 (5): 647 – 653.
  • Pantawane PD and Ahuja BB. Experimental investigations and multi-objective optimization of friction drilling process on AISI 1015. International Journal Of Applied Engineering Research, 2011; Dindigul 2(2): 448 – 461.
  • Chow MH, Lee MS and Yang LD. Machining characteristic study of friction drilling on AISI 304 stainless stell. Journal of Materials Processing Technology, 2008; 207: 180 – 186.
  • Miller SF, Blau PJ and Shih AJ. Tools wear in friction drilling. International journal of Machine Tools and Manufacture, 2007; 47: 1636 – 1645.
  • Miller SF, Wang H, Li R and Shih AJ. Experimental and numerical analysis of the friction drilling process. Journal of Manufacturing Science and Engineering, 2006; 128(3): 802 – 810.
  • Miller SF, Blau PJ and Shih AJ. Tools wear in friction drilling. International of Machine Tool and manufacture, 2007; 47: 1636 – 1645.
  • Dekkers G. Flow Drill Process Company Catalogs, Copyright by Flow Drill BV, Holland, 1993: 1 – 30.
There are 10 citations in total.

Details

Primary Language Turkish
Journal Section Articles
Authors

Cebeli ÖZEK and Zülküf DEMİR - This is me

Publication Date June 1, 2013
Published in Issue Year 2013

Cite

APA -, C. Ö. a. . Z. D. (2013). Investigate the effect of tool conical angle on the bushing height, wall thickness and forming in friction drilling of A7075-T651 aluminum alloy. Usak University Journal of Material Sciences, 2(1), 61-74. https://doi.org/10.12748/uujms/20131712
AMA - CÖaZD. Investigate the effect of tool conical angle on the bushing height, wall thickness and forming in friction drilling of A7075-T651 aluminum alloy. Usak University Journal of Material Sciences. June 2013;2(1):61-74. doi:10.12748/uujms/20131712
Chicago -, Cebeli ÖZEK and Zülküf DEMİR. “Investigate the Effect of Tool Conical Angle on the Bushing Height, Wall Thickness and Forming in Friction Drilling of A7075-T651 Aluminum Alloy”. Usak University Journal of Material Sciences 2, no. 1 (June 2013): 61-74. https://doi.org/10.12748/uujms/20131712.
EndNote - CÖaZD (June 1, 2013) Investigate the effect of tool conical angle on the bushing height, wall thickness and forming in friction drilling of A7075-T651 aluminum alloy. Usak University Journal of Material Sciences 2 1 61–74.
IEEE C. Ö. a. . Z. D. -, “Investigate the effect of tool conical angle on the bushing height, wall thickness and forming in friction drilling of A7075-T651 aluminum alloy”, Usak University Journal of Material Sciences, vol. 2, no. 1, pp. 61–74, 2013, doi: 10.12748/uujms/20131712.
ISNAD -, Cebeli ÖZEK and Zülküf DEMİR. “Investigate the Effect of Tool Conical Angle on the Bushing Height, Wall Thickness and Forming in Friction Drilling of A7075-T651 Aluminum Alloy”. Usak University Journal of Material Sciences 2/1 (June 2013), 61-74. https://doi.org/10.12748/uujms/20131712.
JAMA - CÖaZD. Investigate the effect of tool conical angle on the bushing height, wall thickness and forming in friction drilling of A7075-T651 aluminum alloy. Usak University Journal of Material Sciences. 2013;2:61–74.
MLA -, Cebeli ÖZEK and Zülküf DEMİR. “Investigate the Effect of Tool Conical Angle on the Bushing Height, Wall Thickness and Forming in Friction Drilling of A7075-T651 Aluminum Alloy”. Usak University Journal of Material Sciences, vol. 2, no. 1, 2013, pp. 61-74, doi:10.12748/uujms/20131712.
Vancouver - CÖaZD. Investigate the effect of tool conical angle on the bushing height, wall thickness and forming in friction drilling of A7075-T651 aluminum alloy. Usak University Journal of Material Sciences. 2013;2(1):61-74.