Experimental Investigation of Flow Drilling and Flow Tapping of Thin-Walled Square and Circular Hollow Sections

Yıl 2024, Cilt: 8 Sayı: 2, 188 - 200

Mert Şafak Tunalıoğlu Mehmet Keser

https://doi.org/10.30939/ijastech..1453441

Öz

One of the most important problems of automotive engineering is joining metal sheets, thin-walled tubes or profiles simply, efficiently, and economically. After conventional drilling and tapping in thin-walled materials, the strength remains low due to the small number of teeth and the connection can be easily unfastened. For increasing the strength there are several solutions such as using welded nuts, tapped rivets and welding extra nuts. Since nut welding cannot be done on the inner surfaces, these solutions are inadequate for square and circular tubes. In this study, holes of various diameters were drilled on 1.5 mm thick AISI 304 stainless steel and EN AW-6060 square and circular profiles by flow drilling at various rotational speeds, and then flow tapping was applied to the holes. The same processes were repeated with conventional drilling method to compare bushing heights and clamping strengths of the parts as well as the hardness values and capillary crack formations around the holes. According to the results obtained, the strength in flow drilling and tapping increases by 50-55% compared to the classical drilling method. The reason for this is that as the hole diameter increases, the amount of material plastered and the number of threads required for screwing increases approximately 2.5-3 times. Capillary cracks, which are observed in holes drilled with the traditional method as the hole diameter increases, are not observed with this method and thus increasing the strength of the connection.

Anahtar Kelimeler

Bushing height, Clamping strength, Flow drilling, Flow tap, Traditional drilling

Proje Numarası

MUH19001.17.005

Kaynakça

• [1] Cetin E, Seyitoglu SS. A bibliometric overview of research on auxetic structures: Trends and patterns. International Journal of Automotive Science and Technology, 2024;8(1):65-77. http://dx.doi.org/10.29228/ijastech.
• [2] Karahan OC, Esener E. Determining the Behavior of Door Impact Beam Tubes Under Three Point Bending Loading. In-ternational Journal of Automotive Science and Technology, 2021;5(1):58-62. https://doi.org/10.30939/ijastech..826458
• [3] Xiao WC, Chow WK, Peng W. A discussion on design fires for example high-speed railway train car. International Journal of Automotive Science and Technology, 2022;6(2):141-155. https://doi.org/10.30939/ijastech..1058890
• [4] Öztürk İ. Design of multi-cell tailored property columns under oblique loading. International Journal of Automotive Science and Technology.2021;5(3);266-270. https://doi.org/10.30939/ijastech..961393
• [5] Bicer SG, Katmer MC. Study on flexible dynamic analysis of the wheel loader working conditions and comparison with stat-ic FEA results. Engineering Perspective. 2023;3(4):57-62. http://dx.doi.org/10.29228/eng.pers.72736
• [6] Francis W, Gebre TA. Fatigue and Dynamic Behavior of Pre-stressed Concrete Sleepers. Engineering Perspective. 2022;2(1):1-6. http://dx.doi.org/10.29228/eng.pers.5779 .
• [7] Krasauskas P. Experimental and statistical investigation of thermo mechanical friction drilling process. Mechanika 2011;17(6): 681-686. https://doi.org/10.5755/j01.mech.17.6.1014
• [8] Latour M, Rizzano G. Numerical study on the resistance of thread-fixed one-side bolts: Tensile and bearing strength. Structures, 2021;32:958-972. https://doi.org/10.1016/j.istruc.2021.03.083.
• [9] Liu HQ, Liu YZ, Huo JS. Cyclic behaviour of a novel steel beam-to-prefabricated CFST column connection with threaded sleeve bolts. Structures, 2021;34:615-629. https://doi.org/10.1016/j.istruc.2021.07.079.
• [10] Li YQ, Wu FW, Tan MQ. Static performance of non-through one-side bolted end-plate joint for floor-by-floor as-sembled steel structures. Structures, 2023;48:288-303. https://doi.org/10.1016/j.istruc.2022.12.083.
• [11] Cai M, Liu L, Li S, Cheng T, Jin X, Hao Y, Liu M, Wang P, Liu F. Static behavior of TOBs bolted endplate connection to strengthened HSST with fixed thread length. Structures, 2023;54:478-498. ttps://doi.org/10.1016/j.istruc.2023.05.069
• [12] Cabrera M, Tizani W, Mahmood W, Shamsudin MF. Analy-sis of Extended Hollo-Bolt connections: Combined failure in tension. J. Constr. Steel Res.. 2020; 165-105766. https://doi.org/10.1016/j.jcsr.2019.105766.
• [13] Davison JB, France JE, Kirby PA. Strength and rotational stiffness of simple connections to tubular columns using flowdrill connector. J. Constr. Steel Res. 1999;50:15-34. https://doi.org/10.1016/S0143-974X(98)00236-3.
• [14] Sonstabo JK, Morin D, Langseth M. Macroscopic modelling of flow-drill screw connections in thin-walled aluminum struc-tures. Thin-Walled Structures 2016;105:185-206. https://doi.org/10.1016/j.tws.2016.04.013.
• [15] Sonstabo JK, Holmstrom PH, Morin D. Macroscopic Strength and failure properties of flow-drill screw connections. Journal of Materials Processing Technology 2015;222:1-12. https://doi.org/10.1016/j.jmatprotec.2015.02.031.
• [16] Wang J, Chen L. Experimental investigation of extended end plate joint to concrete-fil steel tubular columns. J. Constr. Steel Res. 2012:79:56-70. https://doi.org/10.1016/j.jcsr.2012.07.016.
• [17] Lee J, Goldsworthy HM, Gad EF. Blind bolted T-stub con-nections to unfilled hollow section columns in low rise struc-tures. J. Constr. Steel Res. 2010;66:981-992. https://doi.org/10.1016/j.jcsr.2010.03.016.
• [18] France JE, Davison JB, Kirby PA. Strength and rotational response of moment connections to tubular columns using flowdrill connectors. J. Constr. Steel Res. 1999;50:1–14. https://doi.org/10.1016/S0143-974X(98)00235-1.
• [19] France JE, Davison JB, Kirby PA. Moment-capacity and rotational stiffness of endplate connections to concrete-filled tubular columns with flowdrilled connectors. J. Constr. Steel Res. 1999;50:35-48 https://doi.org/10.1016/S0143-974X(98)00237-5.
• [20] Li GQ, Liu K, Wang YB, Dai Z. Moment resistance of blind-bolted SHS column splice joint subjected to eccentric com-pression. Thin-Walled Structures 2019;141:184–193. https://doi.org/10.1016/j.tws.2019.04.015.
• [21] Wang W, Li L, Chen D, Xu T. Progressive collapse behavior of extended endplate connection to square hollow column via blind Hollo-Bolts. Thin-Walled Structures 2018;131:681–694. https://doi.org/10.1016/j.tws.2018.07.043.
• [22] Thai HT, Vo TP, Nguyen TK, Pham CH. Explicit simulation of bolted endplate composite beam-to-CFST column connec-tions. Thin-Walled Structures 2017;119:749–759. https://doi.org/10.1016/j.tws.2017.07.013.
• [23] Tizani W, Al-Mughairi A, Owen JS, Pitrakkos T. Rotational stiffness of a blind-bolted connection to concrete-filled tubes using modified Hollo-bolt. J. Constr. Steel Res. 2013;80:317–331. https://doi.org/10.1016/j.jcsr.2012.09.024.
• [24] Wang W, Li L, Chen D. Progressive collapse behavior of endplate connections to cold-formed tubular column with novel Slip-Critical Blind Bolts. Thin-Walled Structures 2018;131:404–416. https://doi.org/10.1016/j.tws.2018.07.012.
• [25] Jeddi MZ, Sulong NHR. Pull-out performance of a novel anchor blind bolt (TubeBolt) for beam to concrete-filled tubu-lar (CFT) column bolted connections. Thin-Walled Structures 2018;124:402–414. https://doi.org/10.1016/j.tws.2017.12.028.
• [26] Wang W, Li M, Chen Y, Jian X. Cyclic behavior of endplate connections to tubular columns with novel slip-critical blind bolts. Engineering Structures 2017;148:949–962. https://doi.org/10.1016/j.engstruct.2017.07.015.
• [27] Miller SF, Blau P, Shih AJ. Microstructural alterations associ-ated with friction drilling of steel, Aluminum and Titanium. Journal of Materials Engineering and Performance 2005;14:647–653. https://doi.org/10.1361/105994905X64558.
• [28] Miller SF, Blau P, Shih AJ. Tool wear in friction drilling. International Journal of Machine Tools and Manufacture 2006;47:1636–1645. https://doi.org/10.1016/j.ijmachtools.2006.10.009.
• [29] Demir Z. An experimental investigation of the effect of depth and diameter of pre-drilling on friction drilling of A7075-T651 alloy. J. Sustain. Construct. Mater. Technol. 2016;1:46–56. https://doi.org/10.29187/jscmt.2017.5
• [30] Ozek C, Demir Z. Investigate the surface roughness and bushing shape in friction drilling of A7075-T651 and St 37 steel. TEM Journal, 2013;2:170-180.
• [31] Demir Z. Investigation of the fluctuation size in thrust force and chip morphology in drilling. Celal Bayar University Jour-nal of Science 2018;14:385-397. https://doi.org/10.18466/cbayarfbe.409399.
• [32] Sua KY, Welo T, Wang J. Improving friction drilling and joining through controlled material flow. Procedia Manufactur-ing 2018;26:663-670. https://doi.org/10.1016/j.promfg.2018.07.077.
• [33] El-Bahloul SA, El-Shourbagy HE, El-Bahloul AM, El-Mindany TT. Experimental and thermo-mechanical modeling optimization of thermal friction drilling for AISI 304 stainless steel. CIRP Journal of Manufacturing Science and Technology, 2018;20:84–92 https://doi.org/10.1016/j.cirpj.2017.10.001.
• [34] Haynes NRJ, Kumar R. Simulation on friction drilling pro-cess of Cu2C. Materials Today: Proceedings, 2018;5:27161–27165 https://doi.org/10.1016/j.matpr.2018.09.026.