U.S.-China Dissertation Enhancement: Exploring the Friction Drilling: An Environmentally Benign Sheet Metal Hole-Making Process

0516906Shih此奖项用于资助施崇棠教授在密歇根大学安娜堡分校的研究生学位论文提升访问，以便与上海交通大学的赵万森教授在中国会面。这一合作研究项目将重点推进摩擦钻探工艺。摩擦钻削是一种用于薄板或薄壁铸件的新型制孔技术，它是通过置换和成形衬套来实现的。衬套为设备的螺纹连接提供了延伸的空间。摩擦钻削以一种干净、无切屑的工艺直接从母金属板材中创建衬套。孔中的所有加工材料都有助于形成衬套。此外，不需要切削液或润滑剂，这使得摩擦钻削工艺成为一种环保的打孔工艺。虽然摩擦钻削的原始专利已全部到期，但由于缺乏刀具几何形状、刀具材料和工艺参数选择等工程信息，该工艺仍未得到很好的了解，在工业上应用较少。本研究项目就是针对这一需求展开的。将开发新技术，以扩大摩擦钻探工艺的应用范围。将开发两个模型：1)使用接触面积和压力的分析模型；2)使用ABAQUS软件建立更复杂的有限元模型，用于大变形、大应变和高温耦合的工作流建模。该方法可以根据被测材料的温度、应力和应变的详细分布情况生成更全面的解，研究结果可应用于汽车、计算机、电子装配等领域。由于这项研究的目的是开发“绿色”钻井工艺，它可以通过减少废物的产生对工业产生影响，从而促进对环境无害的制造。通过消除昂贵的机器人焊接机和车间中的螺母供应，新型摩擦钻探还可以简化工厂生产和库存系统。预计将与橡树岭国家实验室和福特汽车公司密切合作。这一政府-行业-大学-国际合作将通过让研究生接触到旨在保护环境的新型摩擦钻探工艺来帮助人力资源开发。

0516906ShihThis award supports a dissertation enhancement visit to enable Professor Albert Shih's graduate student at the University of Michigan in Ann Arbor to meet with Professor Wan-Sen Zhao at the Shanghai Jiao Tong University in China. This collaborative research project will focus on advancing the friction drilling process. Friction drilling is a novel hole-making technique used on sheet metal or thin wall casting by displacing and forming a bushing. The bushing provides the extended space for thread joining of devices. Friction drilling creates a bushing directly from the parent sheet metal in a clean, chipless process. All work-material from the hole contributes to form the bushing. In addition, no cutting fluid or lubricant is necessary, which makes the friction drilling process an environmentally friendly hole making process. Although the original patents on friction drilling have all expired, this process is still not well understood and it is little used in industry due to the lack of engineering information, such as tool geometry, tool material, and process parameter selection. This research project focuses on this need. Novel techniques will be developed to broaden the scope of applications for the friction drilling process. Two models will be developed: 1) an analytical model using the contact area and pressure and 2) a more complicated finite element modeling using ABAQUS software for modeling of work-flow with coupled large deformation, large strain, and high temperature. This method can generate a more comprehensive solution with the detailed temperature, stress, and strain distribution of the work-material.Results of this research can be applied to the automotive, computer, and electronic assembly. Since the research is aimed at developing "green" drilling processes, it can have an impact on industry by reducing the production of waste and thus advancing environmentally benign manufacturing. The novel friction drilling can also simplify the factory production and inventory system by eliminating the expensive robotic welding machine and supplies of nuts on the shop floor. Close collaboration with Oak Ridge National Laboratory and Ford Motor Company are expected. This government-industry-university-international collaboration will aid in human resource development by exposing a graduate student to novel friction drilling process development with the aim for environmental protection.