Cite the paper
M. Boopathi, S. Shankar, T.C. Kanish (2017). Investigation of Surface Texture Generated by Friction Drilling on Al2024-T6. Mechanics, Materials Science & Engineering, Vol 9. doi:10.2412/mmse.1.19.706
Authors: M. Boopathi, S. Shankar, T.C. Kanish
ABSTRACT. Friction drilling is a nontraditional hole-making process in which, a rotating conical tool uses the heat generated by friction to soften and penetrate a thin workpiece and create a bushing without generating chips. During friction drilling most of the frictional heat is retained in the tool-workpiece interface. The effect of frictional heating is relatively prominent; this causes excessive temperatures in the workpiece and results in undesired material damage and improper bushing formation. To overcome these issues, this study investigates the surface texture generated from friction drilling process to characterize the behaviour of friction drilling on Al2024-T6 material. The surface roughness and integrity are of prime importance for any machined components in terms of aesthetics, tribological considerations, corrosion resistance, subsequent processing advantages, fatigue life improvement as well as precision fit of critical mating surfaces. In this study, in addition to the surface roughness measurement, optical microcopy and Scanning Electron Microscopy (SEM) have been carried out to gain insight into the friction drilled surface. Obtained results from the microstructures depict that the development of the microstructures are affected by the magnitude of the friction forces and the heat produced during the friction drilling process. It is also found that from the micrographs there is no direct micro-structural evidence for melting of work-material in friction drilling.
Keywords: Frictional Drilling, Al2024-T6, Surface topography, Optical Micrographs, Scanning Electron Micrographs.
 A.H. Streppel, H.J.J. Kals, Flow drilling: A preliminary analysis of a new bush-making operation. CIRP Annals-Manufacturing Technology, 1983, 32(1), 167-171.
 E. Brinksmeier, Prediction of tool fracture in drilling, Ann. CIRP. 1990, 39, 97–100.
 J.L. Cantero, M.M. Tardio, J.A. Canteli, M. Marcos, M.H. Miguelez, Dry drilling of alloy Ti–6Al–4V, International Journal of Machine Tools and Manufacture, 2005, 45(11), 1246-1255.
 S.F. Miller, A.J. Shih, Thermo-mechanical finite element modeling of the friction drilling process, Journal of Manufacturing Science and Engineering, 2007, 129(3), 531-538.
 P. Krasauskas, Experimental and statistical investigation of thermo-mechanical friction drilling process, Mechanics, 2012, 17(6), 681-686.
 S.F. Miller, P.J. Blau, A.J. Shih, Tool wear in friction drilling, International Journal of Machine Tools and Manufacture, 2007, 47(10), 1636-1645.
 S.M. Lee, H.M. Chow, F.Y. Huang, B.H. Yan, Friction drilling of austenitic stainless steel by uncoated and PVD AlCrN-and TiAlN-coated tungsten carbide tools, International Journal of Machine Tools and Manufacture, 2009, 49(1), 81-88.
 M.T. Kaya, A. Aktas, B. Beylergil, H.K. Akyildiz, An Experimental Study on Friction Drilling of ST12 Steel, Transactions of the Canadian Society for Mechanical Engineering, 2014, 38(3), 319-329.
 S.F. Miller, J. Tao, A.J. Shih, Friction drilling of cast metals, International Journal of Machine Tools and Manufacture, 2006, 46(12), 1526-1535.
 M. Boopathi, S. Shankar, S. Manikandakumar, R. Ramesh, Experimental investigation of friction drilling on brass, aluminium and stainless steel. Procedia Engineering, 2013, 64, 1219-26.
 D. Biermann, Y. Liu, Innovative flow drilling on magnesium wrought alloy AZ31, Procedia CIRP, 2014, 18, 209-214.
 S.F. Miller, A.J. Shih, P.J. Blau, Microstructural alterations associated with friction drilling of steel, aluminium and titanium, Journal of Materials Engineering and Performance, 2005, 14(5), 647-653.
 H.M. Chow, S.M. Lee, L.D. Yang, Machining characteristic study of friction drilling on AISI 304 stainless steel, Journal of materials processing technology, 2008, 207(1), 180-186.
Mechanics, Materials Science & Engineering Journal by Magnolithe GmbH is licensed under a Creative Commons Attribution 4.0 International License.
Based on a work at www.mmse.xyz.