Experimental and Thermo-Mechanical Modeling Optimization of Thermal Friction Drilling for AISI 304 Stainless steel

El-Bahloul, Sara A.; El-Shourbagy, Hazem E.; El-Bahloul, Ahmed M.M.; El-Midany, T. T.

doi:10.1016/j.cirpj.2017.10.001

Cited by 32 publications

(19 citation statements)

References 4 publications

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“…In that paper, the thermal-friction-drilling method applied to the AISI 304 stainless steel material with depths of 2 mm and 3 mm was drilled using conical tools with diameters of (5.4, 7.3 and 9.2) mm. In paper, 3 the mean bushing height of approximately 8.5 mm was gained at a diameter of 7.3 mm and a depth of 3 mm. Moreover, the author gained a bushing height (length) of 10.86 mm using a hole diameter of 9.2 mm and material depth of 3 mm.…”

Section: Methodsmentioning

confidence: 99%

“…2 Moreover, a higher bushing length leads to a larger screwing area as well as increasing the connection strength of the sheet materials. 3 The bushing shape, especially the geometrical dimensions of a bushing, such as the bushing height and wall thickness, depends on both the thickness of the drilled material and the diameter of the thermal friction drilled hole, and hence it depends on the ratio (t/d) of the material thickness (t) to the hole diameter (d). 4 The bushing shape requires five steps to be complete and categorized according to the geometrical regions of the conical tool and proceeding dimension of the tool sinking into the material.…”

Section: Introductionmentioning

confidence: 99%

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A geometrical approach to deriving a bushing height equation for thermal friction drilling

Demir¹

2019

Mater. Tehnol.

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The main purpose of thermal friction drilling is to increase the connection strength with the help of bushing formation. Therefore, the bushing formation and its geometry are of great interest. In this study, the bushing shapes obtained from the literature are analyzed geometrically according to their outer curve lines. These curve lines resemble a graph of parabola with varying slopes. The total volume of the evacuated material is completed when the tool cylindrical region sinks into the workpiece (t) mm in depth. It is accepted that approximately by the time when the tip of the tool reaches the half thickness of the material, the evacuated material forms a flake. By subtracting the flake volume (VC) from the total evacuated-material volume (VE), the volume of the bushing shape (VB) is determined. From the obtained equation, the bushing height is found, depending on the hole diameter (d), sheet-material thickness (t), tool conical angle (b), feed rate (f), which can be selected by the operator, and also equation constant μ. Using the bushing-height values, gained from the literature, the limit of the constant is specified as 0.001 £ μ £ 1.2 for thermal friction drilling of all kinds of materials. By comparing the experimental bushing-height results, obtained from the literature, with the modeling data, it is observed that the equation constant (μ) shows a simultaneous alteration with the material thickness (t), hole diameter (d) and tool conical angle (b), but an adverse alteration with the feed rate (f).Glavni namen termi~nega tornega vrtanja je pove~anje vezne trdnosti med osnovnim materialom in med vrtanjem za vrtino nastalo posebno obliko (blazinico). Zato sta nastanek te blazinice za vrtino in njena geometrija zelo zanimiva. Avtorji geometri~no analizirajo blazinice, nastale po tornem vrtanju, glede na njihov zunanji obris. Podatke o njihovih geometrijah so zbrali v podani literaturi. Obrisi nastalih blazinic spominjajo na parabole z razli~nim nagibom. Pretvorba izvrtanega materiala v blazinico se zaklju~i, ko se cilindri~ni del vrtala potopi v material za globino (t) v mm. Splo{no je sprejeto, da dokler konica vrtala ne dose`e pribli`no polovice debeline materiala, izvrtani material tvori obliko ostru`ka. Z od{tevanjem volumna ostru`ka (VC) od celotnega volumna (VE) lahko izra~unamo volumen nastale blazinice (VB). Vi{ino nastale blazinice lahko tako izra~unamo v odvisnosti od premera vrtine (d), debeline materiala (t), kota konice vrtala (b), hitrosti prodiranja vrtala v material (f), ki jo dolo~i/izbere operater na stroju in konstante μ. Iz podatkov, zbranih v literaturi za nastale vi{ine blazinic, ima konstanta vrednosti med 0.001 £ μ £ 1.2 za termi~no vrtanje vseh vrst materialov. Primerjava eksperimentalnih rezultatov za vi{ino blazinice, dobljenih v literaturi, z modelnimi podatki ka`e, da je konstanta (μ) isto~asno odvisna od debeline materiala (t), premera vrtine (d), koni~nosti konice vrtala (b), medtem ko ima hitrost prodiranja vrtala v material (f) obraten u~inek. Klju~ne besede: termi~no torno v...

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Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

A geometrical approach to deriving a bushing height equation for thermal friction drilling

Demir¹

2019

Mater. Tehnol.

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“…With increasing both the material thicknesses (t) and hole diameters (d) the value of the ratio (r) change from 61 % to 84 %. The density values of bushings, derived from thermal friction drilling operations of A7075-T651 aluminum alloys, 2, 4, 6, 8, and 10 mm in thicknesses, changed from 2.54 g/ cm 3 to 2.75 g/ cm 3 , while the density of the selected samples was 2.7 g/ cm 3 . Although the density of the samples with 4 mm and 6 mm in thicknesses showed different values from the other selected samples, the density of the bushing was changed in small and inconsiderable quantity, as seen in Figure 11.…”

Section: The Density and The Volume Ratio Of The Bushingmentioning

confidence: 99%

“…It is generally desired to obtain only the bushings with a cylindrical shape, having no cracks and petal formations, in order to increases the connecting strength [2]. Higher bushing length leads to a more screwing area as well as increasing the connection strength in sheet materials [3]. Bushing shape, especially bushing height and wall thickness, depends on both the thickness of the drilled material (t) and the diameter of the hole (d), and hence it depends on the ratio of (t/d) [4].…”

Section: Introductionmentioning

confidence: 99%

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An Experimental Investigation on Bushing Geometrical Properties and Density, in Thermal Frictional Drilling

Demir¹,

Özek²,

Bal³

2018

Preprint

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In thermal friction drilling (TFD) operations, the geometrical dimensions of bushing shape, height and wall thickness are the most vital consequences, due to increasing the connecting length and strength. In this paper, AA7075-T651 aluminum alloys with 2, 4, 6, 8, and 10 mm in thicknesses were drilled with TFD process in order to investigate the density, the volume ratio, and height and wall thickness of the bushings. The experiments were conducted at constant spindle speed and feed rate conditions by using HSS conical tools of 5, 10, 15, and 20 mm in diameters. It was experimentally found that the bushing height and the wall thickness were tendency of increase linearly with increasing both material thickness and tool diameter. The effect of tool diameter was found to have much of influence on the measured values than the thickness of the drilled material. The density of the bushing was changed inconsiderably. Approximately 70-75 % percentages of the evacuated material composed the bushing shape, in TFD operations.

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Forming Quality and Microstructure Evolution of AA6061‐T6 Aluminum Alloy Joint during Flow Drill Screwing Process

Huang

Shan³

et al. 2023

Adv Eng Mater

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Flow drill screwing (FDS) is the optimal process to realize the single‐side connection of metal sheets. However, the plastic deformation and high fractional temperature during the plate connection process significantly impact the mechanical properties and microstructure of the metal sheets. Herein, the AA6061‐T6 sheet is connected by the FDS process, and the forming quality and microstructure evolution of the alloy are studied. The results show that the plate and the screw are mechanically connected. Obvious plastic deformation and recrystallization occur in the aluminum alloy around the screw, resulting in a fine‐grained zone near the joint interface. The recrystallization phenomenon in the central bushing region promotes the intermolecular fusion between the plates. The high temperature in the connection process partially promotes the dissolution of the strengthening phase, resulting in a decreased strength of the alloy matrix near the screw. The softening zone and hardening zone appear in the plates after the connection, and the hardness values are 55.8% and 105.7% of the alloy matrix.

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Experimental and Thermo-Mechanical Modeling Optimization of Thermal Friction Drilling for AISI 304 Stainless steel

Cited by 32 publications

References 4 publications

A geometrical approach to deriving a bushing height equation for thermal friction drilling

A geometrical approach to deriving a bushing height equation for thermal friction drilling

An Experimental Investigation on Bushing Geometrical Properties and Density, in Thermal Frictional Drilling

Forming Quality and Microstructure Evolution of AA6061‐T6 Aluminum Alloy Joint during Flow Drill Screwing Process

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