3D Finite Element Modeling and Simulation of Friction Drilling Process

Abstract

Friction drilling is an advanced drilling process in which that can be utilize the heat produced between the workpiece and rotating drilling tool bit to soften the work material and producing a hole on it. In this investigation our interest is to choose work material is Al 7075-T351 to analyze the stress, strain, temperature and work material deformation in friction drilling. Al 7075-T351 square-tube materials were drilled on a computer numerical control (CNC) machine centre by friction drilling has analyzed at different rotational speed and feed rate through controlled operation tests. The temperatures in work piece and tool were more in Friction drilling. Simulation has required perceiving the material flow, stresses, temperatures, and strains. Those are tough to quantify experimentally through friction drilling. In this study, CATIA is used to design the tool model and the software which is used to simulate the performance of friction drilling is DEFORM-3D and effect of tool material speed and feed rate on shape of bushing formed is observed. Taguchi’s technique L9 Orthogonal Array was used to analyze the optimum values. Signal to noise ratios also administered for optimization of parameters.