Process analyses of friction drilling using the Smoothed Particle Galerkin method

Abstract As a cost-effective hole production technique, friction drilling is widely used in industrial and automotive manufacturing. Compared with the traditional bolted connection, it enables fastening of thin metal sheets thin-walled tubular profiles. Friction results higher thread length joint strength, thus better fulfilling demand for lightweight structures. However, numerical simulation drilling, finite element method encounters difficulties caused by extreme deformation complex failure material. A large number elements are usually deleted due to criterion, which significantly reduces solution accuracy. The development meshless methods over past 20 years has alleviated this problem. Especially Smoothed Particle Galerkin (SPG) proposed recent incorporating bond-based mechanism been shown be advantageous material separation simulations. It does not require removal can continuously evolve each particle's information such as strain stress after failure. Therefore, SPG was research frictional HX220 sheet metal. First particle distance coefficient were varied investigate applicability process. Predicted experimental compared found high agreement. Furthermore, influence input parameters, thickness, feed rate rotational speed, on axial force well torque tool surface temperature workpiece during investigated numerically.