Friction Drilling of Cast Aluminum Alloy A380 Without Significant Petal Formation and Radial Fracture

  • Sara Ahmed El-BahloulEmail author
Regular Paper


Cast aluminum alloy A380 is one of the most commonly specified alloys that has light weight and exhibits excellent resistance to hot cracking, which makes it necessary in many industrial applications. An idea is investigated to generate a cylindrical bushing without significant petal formation and radial fracture that are expected to be obtained by friction drilling of cast metals. Three materials; namely, 316 stainless steel, Al6060 aluminum alloy, and red copper alloy are used in which each of them is located on the upper and lower surfaces of A380 workpiece, so achieving the idea of the functionally graded material. The process parameters were studied for reducing the resultant axial force, the gap between surfaces, and achieving a longer bushing without petal formation and radial fracture. Lower feed rate achieves minimum axial force and gap thickness with maximum bushing length for all material sandwiches. An optimized decision making by the help of fuzzy logic techniques is performed, revealing that red copper sandwich exhibits the optimal multiple performance characteristic index based on axial force, bushing length, gap thickness, and gap divergence.


Thermal friction drilling Cast aluminum alloy Axial force Bushing length Gap thickness Gap divergence 

List of Symbols


Normalized axial force, bushing length, gap thickness, or gap divergence for every experiment number p


Axial force, bushing length, gap thickness, or gap divergence for an experiment number p


Maximum value of the axial force, bushing length, gap thickness, or gap divergence for all experiment


Minimum value of the axial force, bushing length, gap thickness, or gap divergence for all experiment



The author would like to acknowledge Flowdrill Company—Netherlands for offering the needed tools. Also, she would like to acknowledge Shoman Company—Egypt for the valuable support in manufacturing the used thermal friction drilling machine.


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Copyright information

© Korean Society for Precision Engineering 2019

Authors and Affiliations

  1. 1.Production and Mechanical Design Engineering Department, Faculty of EngineeringMansoura UniversityMansouraEgypt

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