Finite-element simulation and validation of material flow in thermal drilling process

  • R. Kumar
  • N. Rajesh Jesudoss Hynes
Technical Paper


Galvanized steel is broadly employed in metal roofing, air conditioning duct, support beams, construction materials, and domestic appliances, etc. In conventional drilling method has limitations such as asymmetrical holes, as well as formation of crack inside the hole made in sheet metal. This problem was entirely exterminated in thermal drilling (TD) process. In the course of TD process, the high temperature was developed due to rotational and feed rate of thermal drill into the workpiece. Owing to this reason, the thermal drill pierces workpiece effortlessly. However, in this process, workpiece deformation is very high; therefore, finite-element simulation is used to study the material flow which is challenging in experimental method. According to finite-element method (FEM), the finite-element analysis of TD process was conducted by the DEFORM-3D simulation software. The aim of this study is to conduct an experimental investigation of TD process on galvanized steel (GS), and then, it is compared to numerical results obtained from the FEM. Between experimental and FEM simulation of TD process, a good relationship was found.


Thermal drilling Material flow Temperature distribution Optical microstructure Simulation 


  1. 1.
    Ozler L, Dogru N (2013) An experimental investigation of hole geometry in friction drilling. Mater Manuf Process 28:470–475. CrossRefGoogle Scholar
  2. 2.
    Ku WL, Hung CL, Lee SM, Chow HM (2011) Optimization in thermal friction drilling for SUS 304 stainless steel. Int J Adv Manuf Tech 53:935–944. CrossRefGoogle Scholar
  3. 3.
    Hynes NRJ, Kumar R (2017) Process optimization for maximizing bushing length in thermal drilling using integrated ANN-SA approach. J Braz Soc Mech Sci Eng. Google Scholar
  4. 4.
    Hynes NRJ, Maheshwaran MV (2016) Numerical analysis on thermal drilling of aluminum metal matrix composite. AIP Conf Proc 1728:1–4. Google Scholar
  5. 5.
    Raju BP, Kumaraswamy M (2012) Finite element simulation of a friction drilling process using deform-3D. Int J Eng Res App 2(6):716–721Google Scholar
  6. 6.
    Miller SF, Wang H, Li R, Shih AJ (2006) Experimental and numerical analysis of the friction drilling process. J Manuf Sci Eng 128(3):802–810. CrossRefGoogle Scholar
  7. 7.
    Miller SF, Shih AJ (2007) Thermo-mechanical finite element modeling of the friction drilling process. J Manuf Sci Eng 129:531–538. CrossRefGoogle Scholar
  8. 8.
    Krasauskas P, Kilikevičius S, Česnavičius R, Pačenga D (2014) Experimental analysis and numerical simulation of the stainless AISI 304 steel friction drilling process. Mecha 20(6):590–595. Google Scholar
  9. 9.
    Bilgin MB, Gok K, Gok A (2015) Three-dimensional finite element model of friction drilling process in hot forming processes. Proc IMechE Part E 231(3):548–554. Google Scholar
  10. 10.
    Eliseev AA, Fortuna SV, Kolubaev EA, Kalashnikova TA (2017) Microstructure modification of 2024 aluminum alloy produced by friction drilling. Mater Sci Eng A 691:121–125. CrossRefGoogle Scholar
  11. 11.
    Miller SF, Blau P, Shih AJ (2005) Micostructural alterations associated with friction drilling of steel, aluminum, and titanium. J Mater Eng Perform 14(5):647–653. CrossRefGoogle Scholar
  12. 12.
    Kim D, Badarinarayan H, Ryu I, Kim JH, Kim C, Okamoto K, Wagoner RH, Chung K (2010) Numerical simulation of friction stir spot welding process for aluminum alloys. Met Mater Int 16(2):323–332. CrossRefGoogle Scholar
  13. 13.
    Zinati RF, Razfar MR (2015) Finite element simulation and experimental investigation of friction stir processing of polyamide 6. Proc IMechE Part B 229(12):2205–2215. CrossRefGoogle Scholar
  14. 14.
    Pashazadeh H, Masoumi A, Teimournezhad J (2013) A study on material flow pattern in friction stir welding using finite element method. Proc IMechE Part B 227(10):1453–1466. CrossRefGoogle Scholar
  15. 15.
    Baek SW, Choi DH, Lee CY, Ahn BW, Yeon YM, Song K, Jung SB (2010) Microstructure and mechanical properties of friction stir spot welded galvanized steel. Mater Trans 51(5):1044–1050. CrossRefGoogle Scholar
  16. 16.
    Viňáš J, Kaščák L, Greš M (2016) Optimization of resistance spot welding parameters for microalloyed steel sheets. Open Eng 6:504–510. Google Scholar
  17. 17.
    Mazzaferro CCP, Rosendo TS, Tier MAD, Mazzaferro JAE, Santos JFD, Strohaecker TR (2015) Microstructural and mechanical observations of a galvanized trip steel after friction stir spot welding. Mater Manuf Process 30(9):1090–1103. CrossRefGoogle Scholar

Copyright information

© The Brazilian Society of Mechanical Sciences and Engineering 2018

Authors and Affiliations

  1. 1.Department of Mechanical EngineeringMepco Schlenk Engineering CollegeSivakasiIndia

Personalised recommendations