Finite Element and Finite Volume Modelling of Friction Drilling HSLA Steel under Experimental Comparison

authored by: Bernd Arno Behrens, Klaus Dröder, André Hürkamp, Marcel Droß, Hendrik Wester, Eugen Stockburger
Abstract: Friction drilling is a widely used process to produce bushings in sheet materials, which are processed further by thread forming to create a connection port. Previous studies focused on the process parameters and did not pay detailed attention to the material flow of the bushing. In order to describe the material behaviour during a friction drilling process realistically, a detailed material characterisation was carried out. Temperature, strain rate, and rolling direction dependent tensile tests were performed. The results were used to parametrise the Johnson–Cook hardening and failure model. With the material data, numerical models of the friction drilling were created using the finite element method in 3D as well as 2D, and the finite volume method in 3D. Furthermore, friction drilling tests were carried out and analysed. The experimental results were compared with the numerical findings to evaluate which modelling method could describe the friction drilling process best. Highest imaging quality to reality was shown by the finite volume method in comparison to the experiments regarding the material flow and the geometry of the bushing.
Organisation(s): Institute of Metal Forming and Metal Forming Machines
External Organisation(s): Technische Universität Braunschweig
Type: Article
Journal: Materials
Volume: 14
No. of pages: 17
ISSN: 1996-1944
Publication date: 12.10.2021
Publication status: Published
Peer reviewed: Yes
ASJC Scopus subject areas: Materials Science(all), Condensed Matter Physics
Electronic version(s): https://doi.org/10.3390/ma14205997 (Access: Open)
: Details in the research portal "Research@Leibniz University"

BibTeX

@article{53b52cc7059546d7854c50bc88cf7d8f,
title = "Finite Element and Finite Volume Modelling of Friction Drilling HSLA Steel under Experimental Comparison",
abstract = "Friction drilling is a widely used process to produce bushings in sheet materials, which are processed further by thread forming to create a connection port. Previous studies focused on the process parameters and did not pay detailed attention to the material flow of the bushing. In order to describe the material behaviour during a friction drilling process realistically, a detailed material characterisation was carried out. Temperature, strain rate, and rolling direction dependent tensile tests were performed. The results were used to parametrise the Johnson–Cook hardening and failure model. With the material data, numerical models of the friction drilling were created using the finite element method in 3D as well as 2D, and the finite volume method in 3D. Furthermore, friction drilling tests were carried out and analysed. The experimental results were compared with the numerical findings to evaluate which modelling method could describe the friction drilling process best. Highest imaging quality to reality was shown by the finite volume method in comparison to the experiments regarding the material flow and the geometry of the bushing.",
keywords = "Friction drilling, High-strength low-alloy steel, Material characterisation, Material modelling, Tensile testing",
author = "Behrens, {Bernd Arno} and Klaus Dr{\"o}der and Andr{\'e} H{\"u}rkamp and Marcel Dro{\ss} and Hendrik Wester and Eugen Stockburger",
note = "Funding Information: Funding: This research was funded by the Federal Ministry for Economic Affairs and Energy on the basis of a decision of the German Bundestag. It was organised by the German Federation of Industrial Research Associations (Arbeitsgemeinschaft industrieller Forschungsvereinigungen, AiF) as part of the program for Industrial Collective Research (Industrielle Gemeinschaftsforschung, IGF) under grant number 20711N.",
year = "2021",
month = oct,
day = "12",
doi = "10.3390/ma14205997",
language = "English",
volume = "14",
journal = "Materials",
issn = "1996-1944",
publisher = "MDPI AG",
number = "20",
}