Method of Selecting a Rational Strategy in Sustainable Friction Drilling

Abstract

The presented paper contains a description of a new method of determining the optimum feed rate for a waste-free, energy-efficient drilling process being a friction drilling. Previous experience has shown that the energy required to drill a hole by friction drilling is closely correlated with the drilling cycle time. Based on the authors’ own experi-ence, the thesis was put forward that the optimum feed rate during the drilling procedure should be variable but smooth. Additional evaluation criteria for the developed method were the drilling cycle time, the maximum values of the axial force and torque, the maximum values of the feed drive and machine spindle drive load, as well as the energy consumption. The test rig was based on a numerically controlled machine tool, equipped with an axial force and torque sensor, and additional dedicated measuring devices for measuring energy consumption. The results of the study indicate the high competitiveness of the developed approach, compared to the feed rate control strategies in a friction drilling cycle known from the literature. The proposed approach for selecting the longitudinal feed rate can quickly gain a significant number of applications. Studies have shown that optimally planned feed rates can reduce energy intensity by up to 47%.