Experimental Investigation On Friction Drilling Of Magnesium Alloy And Sandwich Material

Abstract

Friction drilling is an innovative technique in the field of manufacturing, particularly designed for sheet metal application were in frictional heat generated between the work piece and conical tool is used to produce a hole without generating any chips. The excess material extrudes both sides of the work piece called as bosh and bush. Bosh replaces the function of washer and bush replaces the nut and hence aids in fastening process. The present study investigates the effect of thrust force and torque on the bushing height and the surface roughness of the drilled hole. newline newlineIn this research Magnesium alloy (AZ31B) and AA5052/LDH- epoxy/glass fiber/LDH-epoxy/AA5052 were selected as work piece material and the friction drilling tool was made of H13 steel. The work materials were chosen as there is high demand for light weight materials in automotive, aerospace. The performance of H13 steel with surface treatment plasma nitriding and liquid nitriding and PVD TiN coating were compared in order to achieve the maximum bushing height, minimize surface roughness, thrust force and torque. The input parameters namely spindle speed and feed rate newline newline newlinesignificantly affects the friction drilling process. Hence the spindle speed and feed rate was varied from 2500 rpm to 4000 rpm and 50 mm/rev to newline200 mm/rev respectively. The optimization of the friction drilling process was carried out using RSM. Analysis of variance method was used for collecting experimental data. The PVD TiN coated H13 tool exhibited a hardness value of 576.9 HV along the edge and 526.13 HV in the inner substrate and the average coating thickness of 144 µm was achieved in the tool which was more than any other samples. Wear test was performed using pin on disk method, the initial and final wear rate was calculated. Based on the study it was observed that 0.01481 g was the least material loss for PVD TiN Coated H13 tool. The results were compared and validated with experimental data and RSM. The minimum thrust force observed was 412.0