Experimental investigation on friction drilling of titanium alloy

Dehghan, S.; Ismail, M.; Ariffin, M.; Baharudin, B.

Abstract: Friction drilling is a green hole-making process that zealously utilizes the heat generated from the friction between the rotating conical tool and workpiece to create a bushing without generating chip. The difficult-to-machine materials with unique metallurgical properties have been developed to meet the demands of extreme applications. However, the major challenges of friction drilling on difficult-to-machine materials are the hole diameter accuracy, petal formation and tool wear. In this study, the effects of process parameters such as spindle speed and feed rate on bushing height and shape, hardness and tool wear in friction drilling of titanium alloy Ti-6Al-4V were experimentally investigated using tungsten carbide tool. Optical photographs have also been analyzed for better understanding of the chipless friction drilling process for different parametric settings. Experimental results indicated that the spindle speed has great influences for achieving better bushing formation and prolong the tool life. It was confirmed that the low spindle speed and low feed rate have great influences for achieving better bushing shape and height, prolong tool life and lower hardness that located adjacent to the hole wall. It also was discovered that the low thermal conductivity of Ti-6Al-4V caused to improper increment of frictional heat and surface temperature. This disadvantage leads to unsatisfactory bushing formation. This work demonstrated the performances of chipless friction drilling used on difficult-to-machine material that can offer a great prospective for a new product design and manufacturing.

How to cite this paper

        APA: Dehghan, S., Ismail, M., Ariffin, M & Baharudin, B. (2018). Experimental investigation on friction drilling of titanium alloy. Engineering Solid Mechanics, 6(2), 135-142.
    

        Chicago/Turabian: Dehghan, S., Ismail, M., Ariffin, M & Baharudin, B. 2018. "Experimental investigation on friction drilling of titanium alloy." Engineering Solid Mechanics 6, no. 2 (2018): 135-142.
    

        AMA: Dehghan, S., Ismail, M., Ariffin, M & Baharudin, B. Experimental investigation on friction drilling of titanium alloy. Engineering Solid Mechanics. 2018;6(2):135-142.
    

References

Calamaz, M., Coupard, D., & Girot, F. (2008). A new material model for 2D numerical simulation of serrated chip formation when machining titanium alloy Ti–6Al–4V. International Journal of Machine Tools and Manufacture, 48(3), 275–288.
Hong, S. Y., Ding, Y., & Jeong, W. (2001). Friction and cutting forces in cryogenic machining of Ti–6Al–4V. International Journal of Machine Tools and Manufacture, 41(15), 2271–2285.
Ku, W. L., Hung, C. L., Lee, S. M., & Chow, H. M. (2011). Optimization in thermal friction drilling for SUS 304 stainless steel. International Journal of Advanced Manufacturing Technology, 53(9–12), 935–944.
Lee, S., Chow, H., & Yan, B. (2007). Friction Drilling of IN-713LC Cast Superalloy. Materials and Manufacturing Processes, (March 2015), 893–897.
Lee, S. M., Chow, H. M., Huang, F. Y., & Yan, B. H. (2009). Friction drilling of austenitic stainless steel by uncoated and PVD AlCrN- and TiAlN-coated tungsten carbide tools. International Journal of Machine Tools and Manufacture, 49(1), 81–88.
Miller, S. F., Blau, P. J., & Shih, A. J. (2005). Microstructural Alterations Associated With Friction Drilling of Steel, Aluminum, and Titanium. Journal of Materials Engineering and Performance, 14(5), 647–653.
Miller, S. F., Blau, P. J., & Shih, A. J. (2007). Tool wear in friction drilling. International Journal of Machine Tools and Manufacture, 47(10), 1636–1645.
Miller, S. F., Li, R., Wang, H., & Shih, A. J. (2006). Experimental and Numerical Analysis of the Friction Drilling Process. Journal of Manufacturing Science and Engineering, 128(3), 802.
Miller, S. F., & Shih, A. J. (2006). Friction Drilling–A Chipless Hole-Making Process. In Proceedings of the ASME International Conference on Manufacturing Science and Engineering, Ypsilanti (Vol. 8).
Mohammadshahi, Y. (2013). A state-of-art survey on TQM applications using MCDM techniques. Decision Science Letters, 2(3), 125-134.
Molinari, A., Musquar, C., & Sutter, G. (2002). Adiabatic shear banding in high speed machining of Ti–6Al–4V: experiments and modeling. International Journal of Plasticity, 18(4), 443–459.
Ozek, C., & Demir, Z. (2013). Investigate the Friction Drilling of Aluminium Alloys According to the Thermal Conductivity. Technology Education Management Informatics, 2(1), 93–101.
Ozler, L., & Dogru, N. (2013). An Experimental Investigation of Hole Geometry in Friction Drilling. Materials and Manufacturing Processes, 28(4), 470–475.
Shokrani, A., Dhokia, V., & Newman, S. T. (2012). Environmentally conscious machining of difficult-to-machine materials with regard to cutting fluids. International Journal of Machine Tools and Manufacture, 57, 83–101.
Zhu, Z., Sui, S., Sun, J., Li, J., & Li, Y. (2017). Investigation on performance characteristics in drilling of Ti6Al4V alloy. The International Journal of Advanced Manufacturing Technology, 1–10.