Cutting tool and workpiece deformation in friction drilling of aluminum alloy 6063 by finite element model simulation

Friction drilling is a non-traditional machining process widely used for creating holes in thin metallic sheets without material removal.The process involves severe plastic deformation at elevated temperatures, making it challenging to experimentally measure strain, stress, and deformation.To overcome this limitation, a finite element analysis (FEA) using ANSYS Explicit Dynamics was performed.A definitive screening design (DSD) with 13 runs was employed to investigate the effects of spindle speed, feed rate, workpiece thickness, and tool conical angle on process responses.Equivalent strain, equivalent stress, tool deformation, and workpiece deformation were analyzed across the simulation runs.The results indicate that equivalent strain and stress increase with spindle speed and feed rate, while deformation is primarily governed by workpiece thickness.This study demonstrates that DOE-based simulation provides a reliable framework for understanding complex thermo-mechanical behavior in friction drilling, enabling better tool design and process optimization.