CERTIFICATE

This is to certify that the thesis dissertation titled “OPTIMIZATION OF FRICTION

DRILLING TOOLS BY USING FEM” that is being submitted in partial fulfillment of the

requirements for the award of the Master of Technology in Mechanical Department

Specialized in CAD/CAM from JBIET during the period 2017-2019 is a bonafide report of the

work carried out by him under the guidance and supervision of the undersigned. The results

embodied in this project report have not been submitted to any other, university or institution

for the award of any Master’s Degree.

Signature of Supervisor Signature of HOD

Mr. G.GOPINATH Dr. P.DIVAKARA RAO
Assistant Professor Prof. & HOD Mechanical Engg
JBIET,Hyderabad JBIET,Hyderabad

i
 APPROVAL CERTIFICATE

Viva Voce examination for the dissertation work entitled “OPTIMIZATION OF

FRICTION DRILLING TOOLS BY USING FEM” being submitted by Mr. LOTAVATH
LAXMAN is conducted on………. and the work is approved for the award of MASTER OF
TECHNOLOGY in MECHANICAL ENGINEERING with specialization in CAD/CAM.

INTERNAL EXAMINAR EXTERNAL EXAMINAR

ii
 DECLARATION

I hereby solemnly affirm that the major project entitled “OPTIMIZATION OF

FRICTION DRILLING TOOLS BY USING FEM” is written and submitted by me in practical
fulfilment of the requirement for the award of the Master of Technology in CAD/CAM
Specialization in the department of Mechanical Engineering to the “J.B. Institute of
Engineering and Technology”, is a record of bona fide work carried out by me under the
guidance of Mr.G.GOPINATH, Assistant Professor, Department of Mechanical Engineering
,JBIET,Hyderabad.

Place: Hyderabad Signature of the student

Date: Lotavath Laxman
(17671D0402)

iii
 ACKNOWLEDGEMENT

I would like to thank Dr. S. Sudhakara Reddy,Principal of JBIET for giving me this
opportunity and encouraging me to show our skills in the project of “Optimization Of Friction
Drilling Tools By Using Fem”.I take immense pleasure on thanking the principalof our collegefor
permitting me to carry out this project.
I would like to thank Dr.P.Divakara Rao,Head of the Mechanical Department for
guiding me throughout the project by giving me valuable advice and helping me in preparing the
report.

I would like to thank my project guide and project coordinator Mr. G. Gopinath,
Assistant Professor,JBIET for guiding me throughout the Main project by giving me valuable
advice and also helping me in preparing the report.

Finally, we would like to lend our special thanks to all the persons, who are directly or
indirectly involved in the course of project undertaken, I grateful to one and all.

iv
 INDEX

Chapter Title of the chapter Page No.

No.
Certificate ⅰ
Approval certificate ⅱ
Declaration ⅲ
Acknowledgment ⅳ
Abstract x
1 Introduction
1.1 Drilling 01
1.2 Friction drilling 01
1.3 History 02
1.4 Principle 02
1.5 Tool and Drilling Parameters 03
1.6 Material of Tool and Work 05
1.7 Composition 05
1.8 Process 06
1.9 Drilling in metal 07
1.10 Advantages of Friction Drilling Tools Compare to Other Methods 08
1.11 Advantages 09
1.12 Disadvantages 09
1.13 Material selection 10
1.14 Steel 10
1.15 Al-7075 11
1.16 Mechanical properties 11
1.17 Properties of Al-7075 16
2 Literature review
2.1 Literature survey 17
3 Design And Analysis Softwares
3.1 CAD 24
3.2 Introduction to CREO 24
3.3 Capabilities and Benefits 25

v
 3.4 Features of CREO 25
3.5 CREO Basic Design Modes 26
3.6 Assembly in CREO 26
3.7 Offset 26
3.8 Coincident 27
3.9 CREO Modules 27
3.10 Analysis 27
3.11 ANSYS 31
4 Design And Analysis Of Friction Drilling Tool
4.1 Design developed by using cad tool (creo-2) 33
4.2 Tool dimensions 34
4.3 Assembling of all models 35
4.4 Analysis Process 37
4.5 Thermal Analysis 47
4.6 Manufacturing of tools 55
4.7 Holes Made by Friction Drilling Process 55
5 Results And Discussion
5.1 Results of Static Analysis 57
5.2 Results of Thermal Analysis 59
5.3 200 Friction Drilling Tool 61
0
5.4 40 Friction Drilling Tool 62
0
5.5 60 Friction Drilling Tool 62
5.6 Final Result 63
6 Conclusion 64
7 References 65

vi
 LIST OF TABLES

Table Title of the table Page No.

No.
1.1 Al-alloy composition 06
1.2 Steel composition 10
1.3 Chemical Composition of al-7075 11
2.1 Summary of literature review 22
5.1 20 angle tool all results 57
5.2 40 angle tool all results 57
5.3 60 angle tool all results 57
5.4 Thermal all results for 20 angle tool 59
5.5 Thermal all results for 40 angle tool 60
5.6 Thermal all results for 60 angle tool 60
5.7 Temperature Reading for 200 Tool 61
5.8 Temperature Reading for 400 Tool 62
5.9 Temperature Reading for 600 Tool 62
5.10 Temperature Readings of 200,400,600 Tools 63

vii
 LIST OF FIGURES

Figure Figure Name Page No.

No.
1.1 Friction Drilling Tool Basic Steps 01
1.2 Shape of the typical friction-drilling tool 03
1.3 Bush formed after drilling 04
1.4 Stress strain curve 11
3.1 Basic Steps in ANSYS 29
3.2 Post Processing 30
4.1 Plate 2d sketch 33
4.2 Extrude length of plate 34
4.3 3d modeling of plate 34
4.4 2d dimension of 20 angle tool 34
4.5 Revolve 34
4.6 20 angle final model 35
4.7 Angle final model 35
4.8 60 angle final model 35
4.9 20 angle tool final assembly 35
4.10 40 angle tool final assembly 36
4.11 60 angle tool final assembly 36
4.12 Imaginary drilling holes when we use 20 angle tool 37
4.13 Imaginary drilling holes when we use 40 angle tool 37
4.14 Imaginary drilling holes when we use 60 angle tool 37
4.15 ANSYS workbench modules 38
4.16 Imported model from creo2.0 39
4.17 Meshing 39
4.18 40 angle tool Boundary condition 40
4.19 40 angle tool Boundary condition force, velocity, RPM 40
4.20 40 angle tool Deformation 41
4.21 40 angle tool stress 41
4.22 40 angle tool safety factor 42
4.23 40 angle tool strain 42
4.24 angle tool boundary conditions 43
4.25 angle tool boundary conditions, force, RPM, velocity 43

viii
4.26 angle tool boundary deformation 44
4.27 20 angle tool boundary stress 44
4.28 20 angle tool boundary safety factor 44
4.29 20 angle tool boundary strain 45
4.30 60 angle tool boundary condition 45
4.31 60 angle tool boundary condition, force, RPM, velocity 45
4.32 60 angle tool deformation 46
4.33 60 angle tool stress 46
4.34 60 angle tool safety factor 47
4.35 60 angle tool strain 47
4.36 Thermal module Ansys workbench 48
4.37 Meshing 49
4.38 Angle tool Thermal Boundary conditions 49
4.39 40 angle tool temperature 50
4.40 40 angle tool heat flux 51
4.41 20 angle tool thermal boundary condition 51
4.42 20 angle tool temperature 52
4.43 20 angle tool heat flux 52
4.44 60 angle tool thermal boundary condition 53
4.45 60 angle tool temperature 54
4.46 60 angle tool heat flux 54
4.47 20,40,60 Angle Tools 55
4.48 20 angle tool 55
4.49 40 angle tool 55
4.50 60 angle tool 56
5.1 Deformation static results for 3 tools 58
5.2 Stress static results for 3 tools 58
5.3 Safety factor static results for 3 tools 59
5.4 Strain static results for 3 tools 59
5.5 Thermal total temperature results for all tools 60
5.6 Thermal heat flux results for all tools 61

ix
 ABSTRACT

Friction drilling is a nontraditional hole making process in which a conical rotating tool is
applied to penetrate into work piece and create the hole in a single step, without generating chips.
The process relies on the heat generated due to the frictional force between tool and work piece,
to soften, penetrate and deform the work material into a bushing shape.

In this project we designed complete friction drilling assembly models with different tool
angles by using cad tool (creo-2.o) here we took 40 angle tool as an existing tool and we also
designed 2 more tools (20 angle, 60angle).
After designing here analysing each tool assembly with static and thermal loading
conditions by using cae tool (Ansys workbench) here we took steel material for tool and al-7075
material for plate in each case.By comparing different parameters like static stresses and thermal
conditions then we can get better solution.
Key words: (creo, Ansys workbench, al-7075, steel, tools with different angles, al-7075 plate.)