An investigation of residual stress distribution in friction drilling of AA-7075 sheets by finite element modeling

Articles in Press

Document Type : Original Article

Authors

1 Student at k.n.toosi university of technology

2 Faculty of mechanical engineering

10.22034/ijme.2024.436544.1920

Abstract

The importance of drilling in sheets and material extrusion in machining processes has long been recognized in the industry. The friction drilling process, while reducing material waste, particularly in sheet components, creates a bush-shape to facilitate component connections. In this study, the friction drilling process for sheets of three different thicknesses, three rotational speeds, and three feed rates was designed using ABAQUS finite element software, and the results were analyzed using Design-Expert statistical data analysis software. The response surface methodology (RSM) was used for experimental design in this process. The material chosen for the components was aluminum 7075, a widely used material in automotive, manufacturing, military, and aerospace industries. The results were adjusted to determine the optimal conditions for minimizing machining force and selecting the best parameters, such as maximum rotational speed, minimum feed rate, and component thickness. In this process, higher temperatures are preferable for better material flow, and temperature increases with thickness. The most influential factors affecting component defects in industries affected by residual stresses are important. Since residual stress analysis has not been simulated using finite element analysis in this process so far, residual stresses were examined in different directions. Changes in residual stress near the created hole indicated compressive residual stresses near the hole.

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Iranian Journal of Manufacturing Engineering

Articles in Press, Accepted Manuscript
Available Online from 04 May 2024

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