Friction drilling: a review

TLDR: 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.