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Development of a three-dimensional finite element method simulation model to predict modified flow drilling tool performance

Abstract

Flow drilling is a relatively unexplored manufacturing process in which the tool penetrates the workpiece with a defined force or defined feed along its rotational axis. This paper presents a developed three-dimensional (3D)-finite element method (FEM) simulation model to predict the performance of modified flow drilling tools. To validate the simulation model, the flow drilling of AlSi10Mg with a non-pre-heated (Tinitial = 20 °C) and pre-heated (Tinfluenced = 200 °C) tool was investigated. Thereby, the comparison of measured and simulated values of temperature, force and torques showed a good agreement. The comparison of the forces and torques concluded in almost identical maximum values. Nevertheless, the pre-heated tool was found to have a significantly more continuous heat distribution and higher bore quality than non-pre-heated flow drills, which can be attributed to the better formability of the cast aluminum alloy at elevated temperatures. Since the results of the simulation showed a good agreement with the experimental values, the three-dimensional model was used to predict the process behavior of a modified flow drilling tool, which could contribute to the optimization of the process. The result show, that the process time could be reduced by half, while the occurring temperatures, forces and torques remained acceptable.

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Abbreviations

A :

Initial yield N/mm2

B :

Hardening modulus

Cs :

Strain rate sensitivity

c :

Specific heat, J/(kg∙K)

D :

Cumulative-damage fracture factor

d 1 …d 5 :

Damage constants

d FD :

Tool diameter, mm

d 2 :

Shrank diameter, mm

F :

Force, N

h Cy :

Cylindrical height, mm

h Co :

Conical height, mm

h T :

Tip/center height, mm

k :

Heat conductivity, W/(m∙K)

l :

Length, mm

l t :

Drilling depth (simulation), mm

M t :

Torque, Nm

m :

Thermal softening effect

n :

Rotational speed, 1/min

Rz :

Average surface roughness

t :

Time, s

T :

Homogenous temperature, K

T f :

Friction moment, K

t h :

Thick, mm

T influenced :

Influenced temperature, °C

T initial :

Initial temperature, °C

T m :

Melting temperature, K

T r :

Transition temperature, K

v c :

Peripheral speed

v f :

Feed speed, mm/min

w :

Wide, mm

\( {\dot{q}}_f \) :

Heat generation, m/s

α FD :

Tip/center angle, degree

ε m :

Emission rate

ε plastic :

Plastic strain

β FD :

Conical angle, degree

\( \dot{\varepsilon} \) :

Strain rate, 1/s

\( \dot{\varepsilon_0} \) :

Reference strain rate, 1/s

ε f :

Equivalent strain to fracture, 1/s

\( {\dot{\varepsilon}}_{pl} \) :

Comparative strain rate, 1/s

η :

Hardening exponent

σ :

Flow stress, N/mm2

ρ :

Density, N/m2

ρ h :

Hydrostatic pressure, hPa

ω :

Angular velocity, rad∙s−1

Al:

Aluminum alloy

approx.:

Approximate

Bal.:

Balance

Cu:

Copper

DIN:

German institute for standardization

3D:

Three-dimensional

EN:

European standards

FEM:

Finite element method

FE:

Finite element

Fe:

Iron

Mg:

Magnesium

Mn:

Manganese

Ni:

Nickel

Pb:

Lead

Si:

Silicon

Sn:

Tin

Ti:

Titanium

WC:

Tungsten carbide

x, y, z:

Cartesian coordinates

Zn:

Zinc

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Acknowledgements

The authors gratefully acknowledge funding from the German Research Foundation (DFG) for the research project “Holistic development and characterization of an efficient manufacturing of detachable joints for aluminum and magnesium lightweight materials” (BI498/57).

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Correspondence to Ekrem Oezkaya.

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Oezkaya, E., Hannich, S. & Biermann, D. Development of a three-dimensional finite element method simulation model to predict modified flow drilling tool performance. Int J Mater Form 12, 477–490 (2019). https://doi.org/10.1007/s12289-018-1429-0

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  • DOI: https://doi.org/10.1007/s12289-018-1429-0

Keywords

  • Finite element method
  • Flow drilling
  • Heat exchange
  • 3D modeling
  • 3D FEM flow drilling simulation