PSI - Issue 42

Yahar Sarafraz et al. / Procedia Structural Integrity 42 (2022) 125–132 Author name / Structural Integrity Procedia 00 (2019) 000 – 000

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Fig 2. Manufacturing process to produce M6 threads in AlSi10Mg profile

To reduce the oversizing of the friction drilled bores in cross direction, which can occur due to high thermal mechanical stress by penetrating the conical length of friction drill at the beginning of the process, peripheral and feed speed was reduced by 75% up to a depth of l Con = 6 mm. After complete penetration of the conical tool part, the friction drill speeds were increased to the nominal values.

Tab. 2: Process parameters to manufacture M6 threads in AlSi10Mg profile

Manufacturing steps

Manufacturing parameter

Constant speed

Adapted speed

Pre-drilling (pd)

Tool diameter d pd Tool diameter d fd Peripheral speed v p,fd

2.5 mm

2.5 mm 5.4 mm

5.4 mm / 5.5 mm

Friction drilling (fd)

100 m/min 75 mm/min 40 m/min

75 und 100 m/min 75 und 100 mm/min

Feed speed v f,fd

Internal thread forming (f)

Peripheral speed v p,tf

40 m/min

2.3. Characterization methods Considering the oversizing of the friction drill bore and thread as influential factors on thread strength, dimensional measurements were conducted by CT scan (Nikon XT H 160 system) to determine the dimension of the manufactured specimens (Fig 3).

Fig 3. (a) Dimensional analysis along three different sections of manufactured M6 threads, (b) CT scan setup