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Friction drilling is a nontraditional hole-making process used to create and form the holes in thin sheets. The process involves penetration of a rotating conical tool into a sheet metal work piece and creation of a bushed hole in a single step. The tools are conical without having cutting edges, and the heat caused by friction between the tool and workpiece is used to soften the material, penetrate into the workpiece and make the bush. In this process, the temperature is high, and so that the deformation. The simulation by finite element analysis is a useful tool for understanding the material flow, stress, strain and length of bush. In this research, Abacus software was used to simulate the behavior of friction drilling. To verify the simulation results, the length of bushes created by tools with different diameters at different rotational speeds and federate were measured, and results were compared with experimental data. The aim of this study was to determine the process parameters to provide the bush with a uniform thickness, and study their effect on the shape of bush. Therefore, DOE was performed using a full factorial method and results were interpreted using ANOVA. Results showed that the tool diameter has the greatest effect (95%) on the length of bush during friction drilling, then feed rate (3%) and finally rotational speed (2%) has the smallest effect.

Keywords: Stainless steel AISI 304, Friction drilling, Design of experiment, Finite element simulation

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