A thermo-mechanical finite element simulation model to analyze bushing formation and drilling tool for friction drilling of difficult-to-machine materials
TL;DR: In this article, the authors investigated the effects of frictional heat generation on bushing formation and drilling tool, and how to improve quality of bushing forming and prolong tool life.
About: This article is published in Journal of Manufacturing Processes.The article was published on 2020-09-01. It has received 7 citations till now. The article focuses on the topics: Friction drilling & Bushing.
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TL;DR: In this paper, the effect of spindle speed and feed rate on bushing formation quality and drilling tool performance was investigated experimentally and numerically, both by using the full factorial method.
11 citations
TL;DR: In this article, a detailed material characterisation was carried out to describe the material behaviour during a friction drilling process realistically, and numerical models of the friction drilling were created using the finite element method in 3D as well as 2D.
Abstract: Friction drilling is a widely used process to produce bushings in sheet materials, which are processed further by thread forming to create a connection port. Previous studies focused on the process parameters and did not pay detailed attention to the material flow of the bushing. In order to describe the material behaviour during a friction drilling process realistically, a detailed material characterisation was carried out. Temperature, strain rate, and rolling direction dependent tensile tests were performed. The results were used to parametrise the Johnson–Cook hardening and failure model. With the material data, numerical models of the friction drilling were created using the finite element method in 3D as well as 2D, and the finite volume method in 3D. Furthermore, friction drilling tests were carried out and analysed. The experimental results were compared with the numerical findings to evaluate which modelling method could describe the friction drilling process best. Highest imaging quality to reality was shown by the finite volume method in comparison to the experiments regarding the material flow and the geometry of the bushing.
10 citations
TL;DR: Friction drilling is one of the most promising methods for hole making in thin sheets of conventional structural alloy materials (aluminum, steel, copper, titanium, etc.) and novel polymer composites as mentioned in this paper.
Abstract: Friction drilling is one of the most promising methods for hole making in thin sheets of conventional structural alloy materials (aluminum, steel, copper, titanium, etc.) and novel polymer composites. Despite almost a hundred year history of studying friction drilling, it is still highly relevant and is actively developed. The aim of the present review is to cover as fully as possible all aspects of this technology. The paper analyzes the advantages and disadvantages of friction drilling, discusses the influence of technological parameters on the drilled hole quality. The technological parameters considered are not only the feed rate and spindle speed, but also the tool configuration. The quality of the holes refers to their strength, inner surface hardness, hole geometry and roughness, bushing geometry, and so on; therefore, they are also analyzed. From a fundamental point of view, frictional drilling is interesting in that it causes structural changes in the material as a result of severe plastic deformation, which is discussed in a separate section. Approaches for the process modeling are considered which quite accurately predict the material behavior. A technically more advanced technology of a new generation is discussed, namely flow drill screwdriving. A general conclusion is that despite the widespread use of friction drilling, including by well-known engineering companies, the technology continues to develop with regard to the changing needs of the industry and the market and strengthens its position in the industry.
8 citations
TL;DR: In this article, the effects of dry and cutting oil mixtures containing ceramic particulates on the thrust force, temperature, hole surface quality, bushing profile, and thread stripping strength of the specimens are investigated.
6 citations
TL;DR: In this article, the effect of pre-drilling diameter and depth on the produced bushing cracks and petal formations while drilling cast aluminum alloy (A380) was investigated by using ABAQUS software.
Abstract: Thermal friction drilling is a non-conventional hole making process, which uses a rotating tool to penetrate the workpiece and create a bushing. Friction drilling of brittle cast alloys is likely to result in severe petal forming and radial fracturing. This research investigates the effect of pre-drilling diameter and depth on the produced bushing cracks and petal formations while drilling cast aluminum alloy (A380). A three-dimensional finite element model of high-temperature deformation and large plastic strain is performed by using ABAQUS software. Modeling by using dynamic, temperature-displacement, explicit, as well as the adaptive meshing, element deletion, interior contact, and mass scaling techniques, is necessary to enable the convergence of the solution. The finite element analysis results predict that the pre-drilling has a significant effect on the produced bushing shape. The effect of initial deformation decreases with pre-drilling, leading to fewer cracks and petal formations. Hence, the obtained bushing length increases, so providing a more load-bearing surface that leads to a stiffer joint. Additionally, the effect of pre-drilling on the produced temperature is studied, and the results reveal that by increasing the pre-drilling diameter or depth the temperature decreases. Therefore, less workpiece material melting occurs, which leads to less adhering on the tool surface, so fewer cracks and petal formations.
2 citations
References
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TL;DR: The first crystallographic analysis of a non-γ-tubulin γTuRC component has resulted in a new appreciation of the relationships among all γ TuRC proteins, leading to a refined model of their organization and function.
Abstract: Microtubule nucleation is regulated by the γ-tubulin ring complex (γTuRC) and related γ-tubulin complexes, providing spatial and temporal control over the initiation of microtubule growth. Recent structural work has shed light on the mechanism of γTuRC-based microtubule nucleation, confirming the long-standing hypothesis that the γTuRC functions as a microtubule template. The first crystallographic analysis of a non-γ-tubulin γTuRC component (γ-tubulin complex protein 4 (GCP4)) has resulted in a new appreciation of the relationships among all γTuRC proteins, leading to a refined model of their organization and function. The structures have also suggested an unexpected mechanism for regulating γTuRC activity via conformational modulation of the complex component GCP3. New experiments on γTuRC localization extend these insights, suggesting a direct link between its attachment at specific cellular sites and its activation.
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TL;DR: In this paper, the authors review and identify the materials known as difficult-to-machine and their properties and major health and environmental concerns about their usage in material cutting industries are defined.
Abstract: Machining difficult-to-machine materials such as alloys used in aerospace, nuclear and medical industries are usually accompanied with low productivity, poor surface quality and short tool life. Despite the broad use of the term difficult-to-machine or hard-to-cut materials, the area of these types of materials and their properties are not clear yet. On the other hand, using cutting fluids is a common technique for improving machinability and has been acknowledged since early 20th. However, the environmental and health hazards associated with the use of conventional cutting fluids together with developing governmental regulations have resulted in increasing machining costs. The aim of this paper is to review and identify the materials known as difficult-to-machine and their properties. In addition, different cutting fluids are reviewed and major health and environmental concerns about their usage in material cutting industries are defined. Finally, advances in reducing and/or eliminating the use of conventional cutting fluids are reviewed and discussed.
658 citations
TL;DR: In this paper, the influence of operating parameters of electrical discharge machining of tungsten carbide on the machining characteristics was investigated in terms of the material removal rate, the relative wear ratio and the surface finish quality of the workpiece produced.
359 citations
TL;DR: Titanium alloy is one of the materials extensively used in the aerospace industry due to its excellent properties of high specific strength and corrosion resistance, but it also presents problems wherein it is an extremely difficult material to machine as discussed by the authors.
Abstract: Titanium alloy (Ti–6Al–4V) is one of the materials extensively used in the aerospace industry due to its excellent properties of high specific strength and corrosion resistance, but it also presents problems wherein it is an extremely difficult material to machine. The cost associated with titanium machining is also high due to lower cutting speeds (
293 citations