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Procedia Engineering 00 (2017)000–000

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Procedia Engineering 00 (2017)000–000 www.elsevier.com/locate/procedia
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Procedia Engineering 206 (2017) 985–990

International Conference on Industrial Engineering, ICIE 2017

International Conference on Industrial Engineering, ICIE 2017
Thermal Drilling with Force-Feed Tool
Thermal Drilling with Force-Feed Tool
P.V. Shalamov, Ju.V. Kazantseva*
P.V. Shalamov, Ju.V. Kazantseva*
South Ural State University, 76, Lenin Avenue, Chelyabinsk 454080, The Russian Federation
South Ural State University, 76, Lenin Avenue, Chelyabinsk 454080, The Russian Federation

Abstract
Abstract
To reach the sufficient strength of threaded connection it is necessary to make 3 or more turns of the thread. In bars with the
thickness
To of less
reach the than 2 strength
sufficient mm the of length of screwing
threaded connectionis reached by sheettobending,
it is necessary make 3 connection pressing,
or more turns of the cold stamping
thread. In barsandwithother
the
ways, which
thickness demand
of less than time
2 mmrequirements,
the length ofadditional
screwing is operations,
reached by technical equipment,
sheet bending, workforce.
connection The article
pressing, shows the
cold stamping andway of
other
making thread holes by rotating the punch in sheet blanks. There are five steps of the process
ways, which demand time requirements, additional operations, technical equipment, workforce. The article shows the way ofbeing held. The following steps of
forming holes holes
making thread are used these ways:
by rotating with in
the punch constant load and
sheet blanks. Thereforced feed.steps
are five Theofinfluence of being
the process bar thickness
held. Theand forced feed
following steps on
of
geometry of flanging:
forming holes are usedheightthese and
ways:thickness of upper
with constant andand
load lower extracting
forced feed. The bases has been
influence of considered.
bar thickness Theandexperimental
forced feeddata on
suggest
geometrythat
of reducing
flanging:the bar thickness,
height the height
and thickness and thickness
of upper and lowerofextracting
upper andbases lowerhasflanging
been bases. Herewith
considered. The on bars with 5 data
experimental mm
thickness upper extracting is not being formed. Feed increasing causes reduction of height and increase
suggest that reducing the bar thickness, the height and thickness of upper and lower flanging bases. Herewith on bars with 5 mm in thickness of the upper
and lowerupper
thickness flanging. It can is
extracting benotseen on bars
being withFeed
formed. all kinds of thickness
increasing (0,5...2,0 mm).
causes reduction Theand
of height calculated
increaseand actual strength
in thickness of the of the
upper
gained threaded
and lower flanging.connection
It can beonseensliceonisbars
submitted.
with allAlso
kindsit of
is thickness
clear that (0,5...2,0
the actualmm).strength
The of the gained
calculated andthreaded connection
actual strength is
of the
higher threaded
gained than the connection
calculated one, because
on slice of increasing
is submitted. Also itmicro hardness
is clear that theinactual
the threading zone.
strength of the The result
gained of micro
threaded hardness
connection is
measuring
higher thanisthe assumed.
calculatedTo indentify
one, because the opportunity
of increasingof microusing hardness
this method in thein industry
threadingthe fieldThe
zone. of dissipation
result of microof thehardness
gained
diameter
measuringwas is spotted
assumed. in To
comparison
indentifywiththe the limits by of
opportunity GOSTusing16093-2004.
this methodAlso the gained
in industry thehole
fieldcorresponds to the
of dissipation of 7th
the limit of
gained
accuracy
diameter of
wasthespotted
inner thread diameter,with
in comparison whattheallows
limitsusing this method
by GOST in the industry
16093-2004. Also the[1-7].
gained hole corresponds to the 7th limit of
© 2017 The
accuracy Authors.
of the Published
inner thread by Elsevier
diameter, B.V. using this method in the industry [1-7].
what allows
© 2017 The
Peer-review Authors.
under Published
responsibility by
of Elsevier
the Ltd. committee
scientific of the International Conference on Industrial Engineering.
© 2017 The under
Peer-review Authors. Published by
responsibility of Elsevier
the B.V.committee of
scientific the International Conference on Industrial Engineering
Keywords:
Peer-reviewthinunder
sheet responsibility
workpiece; punch; connection;
of the scientificmicro hardness;oftransmission
committee set; force-feed.
the International Conference on Industrial Engineering.
Keywords: thin sheet workpiece; punch; connection; micro hardness; transmission set; force-feed.

1. Introduction
1. Introduction
In order to ensure operability of threaded connections the screwing length must be sufficient to form at least three
thread turns.toItensure
In order is known that up of
operability to threaded
70% of load falling atthe
connections thescrewing
threadedlength
connection is accounted
must be forform
sufficient to by the first three
at least
thread turns. It is known that up to 70% of load falling at the threaded connection is accounted for by the first three

* Corresponding author. Tel.: +7-950-732-9023; fax:+7-351-267-9273.

E-mail address:author.
* Corresponding juliakzntsv@mail.ru
Tel.: +7-950-732-9023; fax:+7-351-267-9273.
E-mail address: juliakzntsv@mail.ru
1877-7058 © 2017 The Authors. Published by Elsevier B.V.
Peer-review
1877-7058 ©under
2017responsibility
The Authors. of the scientific
Published committee
by Elsevier B.V.of the International Conference on Industrial Engineering .
Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering .

1877-7058 © 2017 The Authors. Published by Elsevier Ltd.

Peer-review under responsibility of the scientific committee of the International Conference on Industrial Engineering.
10.1016/j.proeng.2017.10.582
986 P.V. Shalamov et al. / Procedia Engineering 206 (2017) 985–990
2 P.V. Shalamov, Ju.V. Kazantseva / Procedia Engineering 00 (2017) 000–000

thread turns [8]. There are different methods used to increase the screwing length. They include: plate bending,
molding of plugs, plastic deformation in closed press tools, etc. However, most of the applicable methods are
insufficiently advanced. They require application of special equipment and accessories. It is most expedient to use
the method of plastic deformation of metal blocks by the rotating punch (thermal drilling) [9-14]. The process flows
at heating of the metal block on account of friction forces between the tool and the block. The entire wrought metal
is used to form the upper and lower flanging, thus, ensuring the necessary screwing length and zero-waste process.
The sources describe a process of flanged holes formation by thermal drilling, however, the published data are rather
advertising than scientific. In particular, they do not contain geometrical parameters of the obtained flanging and do
not specify the strength of the obtained threaded connection. It generates a need to determine parameters of the
process of flanged holes forming in 0,8–2,0 mm-thick light-gage metal blocks by thermal drilling ensuring the
necessary screwing length and strength of the threaded connection. One of the tasks necessary for achievement of
this objective is simulation of the hole forming mechanism.

Nomenclature

Fsh shear strength, N

d axial force of process flow, Н
Lsv screwing length, mm
Kg coefficient of fullness
Km coefficient reflecting the uneven deformation of turns adjustment nut in the presence of plastic
deformation
τ shear strength, MPa
h thickness of the workpiece, mm
h1 height of the lower flanging, mm
h2 height of the upper flanging, mm
b0 thickness of the base of the lower flanging, mm
bb thickness of the base of the upper flanging, mm
b1, b2, b3 thickness of the lower flanging in three sections, mm
Fcal calculated shear force, N
Fac actual shear force, N
H hardness, kg/mm2
C length of diagonals of the step, mm
n amount of experiments
Fac average diameter of holes in each experiment on two coordinate axes, mm
хi further nomenclature continues down the page inside the text box
σ standard deviation, mm
∆ confidence interval, mm

2. Geometric parameters of flanging and thread strength

The thermal drilling process can be conventionally divided into five stages [15] (Fig.1).
By the nature of the hole formation process there were recorded five stages (Fig. 1). At the first stage there is a
safety tool cone implement into the workpiece and the beginning of forming the upper hole flanging. At the second
stage – the implement of the tool cone and the beginning of forming the lower-flanging. The third step was to break
the bottom edge of the workpiece. The fourth step was to begin the implement of the cylindrical portion of the tool
into the workpiece. The fifth step was to output the cylindrical portion of the tool and the workpiece in the final
formation the final forming of a hole in the workpiece.
These steps of forming holes observed in the various schemes of formation: at constant load and forced feeding.
The constant load scheme is considered in this paper.
 P.V. Shalamov et al. / Procedia Engineering 206 (2017) 985–990 987
P.V. Shalamov, Ju.V. Kazantseva / Procedia Engineering 00 (2017) 000–000 3

The features in the forced feed process are shown. We conducted a series of experiments with different
thicknesses of workpieces (0,5; 1; 1,5; 2 mm). The forced feed was 0,1 mm/rev; 0,2 mm/rev; 0,4 mm/rev. Flanging
parameters which were measured are shown in the Fig. 2 and their results are in Table 1.

Fig. 1. Stages of flanging holes formation by thermal drilling.

Table 1 Average values of flanging geometry parameters.

Thickness of the Feed, mm /
h1, mm h2, mm Lсв = h1 + h2 + h, mm b0, mm bb, mm b01, mm b02, mm b03, mm
workpiece, mm rev
2 0,1 2,34 1,06 5,4 0,91 0,78 0,76 0,66 0,42
2 0,2 2,35 1,01 5,35 0,98 0,73 0,79 0,65 0,39
2 0,4 2,12 0,88 4,99 1,13 0,8 1 0,86 0,48
1,5 0,1 2 0,79 4,1 0,71 0,48 0,64 0,56 0,28
1,5 0,2 1,84 0,73 4,11 0,95 0,51 0,93 0,69 0,37
1,5 0,4 1,94 0,49 3,89 0,88 0,43 0,86 0,58 0,47
1 0,1 2,09 0,6 3,69 0,78 0,42 0,69 0,51 0,37
1 0,2 1,79 0,45 3,24 0,9 0,48 0,75 0,52 0,33
1 0,4 1,76 – 2,88 1,01 – 0,72 0,64 0,44
0,5 0,1 1,54 – 2,04 0,72 – 0,47 0,37 0,26
0,5 0,2 1,47 – 1,97 0,53 – 0,44 0,42 0,33
0,5 0,4 1,46 – 2,18 0,59 – 0,5 0,39 0,3

Table 2 Results of the calculated and the actual shear strength of the threaded connection
Method of hole formation Calculated shear force, Fcal , N Actual shear force, Fac , N
Common drilling 3165,1 4210
With a load 50H, flanging are cut 3165,1 6320
Forced feed S = 0,1 mm/rev, with flangings 5563,7 8650
Forced feed S = 0,2 mm/rev, with flangings 5495,4 8620
Forced feed S = 0,4 mm/rev, with flangings 5035,5 8630

Table 1 shows that the decrease in thickness of the workpiece reduced height (h1, h2) and thickness (b0, bB) of the
upper and lower base of flangings. This increases the ratio h1/h2 и b0/bB, and on the workpieces 0,5 mm thickness
988 P.V. Shalamov et al. / Procedia Engineering 206 (2017) 985–990
4 P.V. Shalamov, Ju.V. Kazantseva / Procedia Engineering 00 (2017) 000–000

the upper flanging is not formed. By increasing the forced feed the height was reduced and the thickness of the
upper and lower flanging was increased. It is observed, on workpieces of all considered thicknesses. Knowing the
geometric parameters of flangings, it is possible to calculate the shear strength of the threaded connections on the
well-known formula.

Fsh   dLsc Kg Km (1)

Kg which characterizes the contact length of thread (overlapping) coils bolt and nut. For metric thread Kg = 0,8
[12]. Structural steel 08, τ – 200 MPa.
To compare the actual and calculated strength thread shear experiments were conducted to destroy the obtained
threaded connections. The results are shown in Table. 2.
It can be seen that in the holes formed by the forced feeding, the shear strength calculated values and the shear
strength of the thread do not differ by more than 2%. So does the actual strength. The actual thread shear strength is
significantly higher than the calculated one regardless of the nature of the hole formation. It has been suggested that
this is due to hardening of the material in the hole formation area. To confirm this assumption, the strength of the
thread holes values formed by common drilling and the friction drilling were compared. Flangings of the holes
formed by thermal drilling, cut for the same length of screwing.

Fig. 2 -measured parameters: h - thickness of the workpiece, mm; h1 - height of the lower flanging, mm; h2 - height of the upper flanging, mm; b0
- thickness of the base of the lower flanging, mm; bb- thickness of the base of the upper flanging, mm; b1, b2, b3 - thickness of the lower flanging
in three sections, mm.

Fig. 3 - microhardness research: (a) photo of the steps through the Micro Durometer; (b) hardness changing H, kg / mm2, through the cross.
section of the specimen.
 P.V. Shalamov et al. / Procedia Engineering 206 (2017) 985–990 989
P.V. Shalamov, Ju.V. Kazantseva / Procedia Engineering 00 (2017) 000–000 5

The actual shear force in the threaded connections formed by friction drilling is 1.5 times higher than in the holes
formed by common drilling. The strength increasing is associated with the increasing in material hardness. To test
this assumption, we made measurements of the microhardness (14 measurements at a distance of 0.1 mm from each
other, Fig. 3a).
Material hardness H near the hole formation zone determined by indentation diagonals C taking into account the
exerted load (here P=1N) by the formula [14]:

H (1.851  P) / C (2)

The results of the measuring are shown on the graph (Fig. 3 b).
The graph shows that the microhardness of the material near the hole formation zone higher, which explains the
increase in the strength of the threaded connection.

3. Possibility of applying the method of thermal drilling in manufacturing

To determine the possibility of the industrial usage of this method defined the field dissipation of holes' diameter
compared with the tolerance according to GOST 16093-2004 [14]. There were formed 10 holes on the 2 mm
thickness workpiece and there were measured their inner diameters of the upper and lower flangings along the two
mutually perpendicular axes [16-18]. To determine the diameter of the field dissipation the average value of the
sample frame holes’ diameters was calculated according to the formula:

 1 n
x
   xi (3)
n -1 1

The average value does not adequately characterize the sample. To assess the degree of variation (deviation) of
diameter indicators of upper and lower flanging from its average value the concept of standard deviation was used,
which is calculated according to the formula:

1 n
   ( xi  x) 2 (4)
n -1 1

The value of the confidence interval and confidence level depends on the number of measurements . For a small
number of experiments using Student rate. If the confidence level is 0.95 – the Student rate t = 2,3. Then, the
confidence interval is calculated by the formula:

  t y (5)

Confidence interval scatter of the diameters of holes was 0.248 mm for the upper flanging and 0.282 mm for the
lower flanging of the holes. Thus, one can say that the diameter of the upper flanging of the holes will be 4.425
±0.12 mm, of the lower flanging - 4.268±0.14 mm.
These results evidently suggest that the diameter of the lower flanging is smaller. This is due to the shrinkage of
metal during its cooling. The deviation in size is not more than 4%, which provides for sufficient convergence. The
received hole complies with the limit of the inner thread diameter of 7 degree of accuracy, which allows to use this
method in manufacturing [19-21].

4. Conclusions

The research suggested the main conclusions that it was:

1. identified that the thermal drilling process has five stages.
990 P.V. Shalamov et al. / Procedia Engineering 206 (2017) 985–990
6 P.V. Shalamov, Ju.V. Kazantseva / Procedia Engineering 00 (2017) 000–000

2. found that with decreasing thickness of the workpiece the height and thickness of the upper and lower bases of
the flanging reduces.
3. found that the actual thread shear strength is significantly higher than estimated, regardless of the nature of the
hole formation.
4. proved that there is hardening of the material in the hole formation zone.
5. identified that the received hole complies with the limit of the inner thread diameter of 7 degree of accuracy,
which allows to use this method in manufacturing.

Acknowledgements

The work was supported by Act 211 Government of the Russian Federation, contract № 02.A03.21.0011.

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