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Advances in the machining of holes and internal threads in light alloys
Published in Diego Carou, J. Paulo Davim, Machining of Light Alloys, 2018
Carlos Henrique Lauro, Lincoln Cardoso Brandão, Diego Carou, J. Paulo Davim
Miller et al. (2006) analyzed friction drilling (t/d = 0.75) in 4.0-mm-thick sheets of Al380 aluminum alloy and AZ91D magnesium alloy, a lightweight magnesium-aluminum-zinc alloy. Preheating of the workpiece improved the results, reducing the thrust force, torque, energy, and power. For Al380 aluminum alloy, less severe cracking and petal formation on bushings occurred at the higher temperature, 300°C. However, for magnesium alloy, preheating was not employed due to the exothermic oxidation that can ignite inside the oven during heating.
Optimization of coated friction drilling tool for a FML composite
Published in Materials and Manufacturing Processes, 2021
Mathew Alphonse, V. K Bupesh Raja, Manoj Gupta, K. Logesh
One of the latest technologies in the field of manufacturing for making hole is friction drilling process. Among different conventional drilling methods, friction drilling method needs frictional force for making a hole, for that the tool was rotated at high RPM.[1,2] For extrusion of plasticized metal and formation of hole, the frictional heat developed between work piece and tool. As the work piece began to soften, the tool gets started to plunge into the material.[3,4] This makes the material to extrude into front and backside and these extruded portions are known as bosh and bush, respectively. The bosh acts like a washer and bush acts like a support for threading.[5,6] The friction drilling is an attractive choice for application in the field of aerospace and automotive sector.[7] However, the applications are limited due to few limitations such as surface finish and tool life. The use of different geometric shapes for tool by varying Friction Contact Area Ratio (FCAR) of 50% or FCAR of 100% produces better results.[8] Moreover, the temperature of the tool affects the material surface finish.[9] On the other hand, the importance of torque and thrust force are critical to improve the life of the tool.[10,11] These reasons cause several investigators to study the influence of the input parameters such as spindle speed, feed, surface quality, tool life and bushing height.[12,13] In the previous work, the AA5052 Nano Hybrid Sandwich sheet was fabricated through hand layup technique and its properties were characterized.[14] In the present work, friction drilling process was carried out on the AA5052 Nano Hybrid Sandwich sheet. From previous literature survey, it is observed that drilling of Mg Al LDH reinforced FML through friction drilling has not been attempted.