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Abstract:The main purpose of this research is to study the optimal process parameters for thermal friction drilling process on AISI 304 stainless steel. The experiments were conducted based on Taguchi experimental design method, and the multiple performance characteristics correlated with the resultant axial force, radial force, hole diameter dimensional error, roundness error, and bushing length, were investigated by fuzzy logic technique. The significant process parameters that most intensively affected the multiple performance characteristics and the optimal combination levels of process parameters were determined through the analysis of variance and the response graph. A test rig was manufactured at Shoman Company -Egypt to perform the experimental work, and the tools were offered by Flowdrill Company -Germany. Experimental results confirm that this approach is simple, effective and efficient for simultaneous optimization of multiple quality characteristics in thermal friction drilling process, as the bushing length produced is more than five times the workpiece thickness.

Wire electrical discharge machining (WEDM) is a special form of electrical discharge machining that uses a small diameter wire as the electrode to cut a narrow kerf in the workpiece. Although it is a simple concept, the performance of the process is highly dependent on the operating parameters. The aim of this work is to optimize WEDM operating parameters with the objective of achieving a maximum material removal rate (MRR) and minimum surface roughness (SR) for an AISI 304 stainless steel workpiece. This work compares the performance of response surface methodology (RSM) and artificial neural network (ANN) based on the coefficient of determination, root mean square error, and absolute average deviation calculations. This is followed by implementing the fuzzy logic technique to get the optimal operating parameters. The results show that using both the RSM and ANN is more adequate and reliable in predicting the MRR and SR. In addition, it is shown that by increasing the peak current, the pulse on time, and by decreasing pulse off time, the resulting workpiece surface is rougher despite achieving a higher material removal rate. It is concluded that the optimal process parameters combination that achieves the maximum MRR and minimum SR is 25 µs pulse on time, 5 µs pulse off time, and 6 A peak current.

Thermal friction drilling is a novel nontraditional hole-making process. A rotating conical tool is applied to penetrate a hole and create a bushing in a single step without generating chips, providing a more solid connection for attachment than attempting to thread the original sheet. The amazing applications of thermal friction drilling in different industrial fields will lead to new era of joining process for different work materials, especially in the sheet metal applications. The aim of this work is to review the state of the art for researches performed on the friction drilling process as well as its applications considering its advantages and limitations. Thereby, to highlight the important and critical issues that should be tackled and investigated by researchers in the near future such as studying the optimal machining parameters of such process and evaluating their effects on the multiple performance characteristics.

The main purpose of this research paper is to study experimentally the effects of the thermal friction drilling process parameters such as the tool geometry, feed rate, and rotational speed, on the resultant bushing length, axial and radial forces, hole dimensional error, and roundness error, while drilling AISI 304 stainless steel sheets with different thicknesses using tungsten carbide tools. The experiments were conducted based on the design of experiments method. A test rig was manufactured at Showman Company-Egypt to perform the experimental work, and the tools were offered by Flow drill Company-Netherlands. Also Fuzzy Logic technique is applied to the obtained results to find the optimal drilling condition.