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Procedia Engineering 207 (2017) 956–961

International Conference on the Technology of Plasticity, ICTP 2017, 17-22 September 2017,
International Conference on theCambridge,
TechnologyUnited Kingdom
of Plasticity, ICTP 2017, 17-22 September 2017,
Cambridge, United Kingdom
Front Face Flow Drilling of Lightweight Cast Materials
Front Face Flow Drilling of Lightweight Cast Materials
D. Biermanna, F. Waltherb, S. Hannich*a, P. Wittkeb
a
D. Biermanna, F. Waltherb, S. Hannich*a, P. Wittkeb
Institute of Machining Technology, TU Dortmund, Baroper Str. 303, 44227 Dortmund, Germany
b
Department
a
Institute of
of Materials
MachiningTest Engineering,
Technology, TU Dortmund,
TU Dortmund, Baroper
Baroper Str. Str.
303,303, 44227
44227 Dortmund,
Dortmund, Germany
Germany
b
Department of Materials Test Engineering, TU Dortmund, Baroper Str. 303, 44227 Dortmund, Germany

Abstract
Abstract
Front face flow drilling, which has been investigated at the Institute of Machining Technology (ISF), TU Dortmund University,
represents
Front face aflow newdrilling,
application of the
which has conventional
been investigatedflow drilling process.ofWith
at the Institute this newTechnology
Machining technique it(ISF),
is possible to form closed
TU Dortmund holes
University,
with diameters,
represents a newwhich can exceed
application of thethe local wall thickness
conventional flow drilling of the profile.
process. By using
With this newa subsequent
technique itthreading operation,
is possible to form it is possible
closed holes
to generate
with solidwhich
diameters, joints.can
In this article
exceed theinvestigations regarding
local wall thickness theprofile.
of the machining of theaaluminium
By using subsequentcast alloy AlSi10Mg
threading operation,are presented.
it is possible
The feasibility
to generate solidofjoints.
the front facearticle
In this flow drilling application
investigations was analysed
regarding for theofmachining
the machining the aluminiumof thin profiles
cast with a wallarethickness
alloy AlSi10Mg presented.of
tThe
W = feasibility
6 mm. Flow drilling tools with a diameter of d = 5.4 mm have been used. Feed forces as well as
of the front face flow drilling application was analysed for the machining of thin profiles with a wall thickness of
FD torques were measured
during the flow
tW = 6 mm. Flowdrilling process.
drilling In order
tools with to generate
a diameter of dsolid threads,
FD = 5.4 mm ahave
highbeen
quality of the
used. Feedformed
forcesholes has as
as well to be ensured.
torques wereTomeasured
quantify
the quality,
during measurements
the flow of theIncircularity
drilling process. as well as
order to generate thethreads,
solid diameters werequality
a high carriedofout.
the Both
formedaspects
holes can
has have
to be an influencing
ensured. effect
To quantify
on the
the threading
quality, operation. of
measurements Duethetocircularity
the low formability
as well asof thethediameters
used alloys,
wereadjustments
carried out.ofBoth
the flow drilling
aspects process
can have an had to be realised.
influencing effect
Besides
on the variation
the threading of process
operation. Due toparameters such as peripheral
the low formability of the used speed andadjustments
alloys, feed velocity, a pre-heating
of the flow drillingof process
the toolhad
wastoconducted to
be realised.
raise thethe
Besides formability
variationofofthe workpiece
process material
parameters and
such asto increase the
peripheral process
speed and feedstability. Theapre-heating
velocity, pre-heatingofofthethetool
toolwas
wasaccomplished
conducted to
by
raiseusing a portable induction
the formability system material
of the workpiece with an andintegrated temperature
to increase control.
the process As aThe
stability. result of the investigations,
pre-heating of the tool was suitable process
accomplished
strategies
by using awill be recommended
portable regarding
induction system witha stable front face
an integrated flow drilling
temperature operation
control. As of the lightweight
a result cast alloy AlSi10Mg.
of the investigations, Further
suitable process
research regarding front face flow drilling is planned towards an adaptation to magnesium cast alloys.
strategies will be recommended regarding a stable front face flow drilling operation of the lightweight cast alloy AlSi10Mg. Further
research regarding front face flow drilling is planned towards an adaptation to magnesium cast alloys.
© 2017 The Authors. Published by Elsevier Ltd.
© 2017
2017 The
Peer-review
© The under
Authors. Published by
responsibility
Authors. Published by Elsevier Ltd.
the scientific
of Elsevier Ltd. committee of the International Conference on the Technology
Peer-review under responsibility of the scientific committee of the International Conference on the Technology of Plasticity.
of Plasticity
Peer-review . responsibility of the scientific committee of the International Conference on the Technology
under
of Plasticity
Keywords: Flow.Drilling, Cast Material, Process Loads, Bore quality, Aluminium
Keywords: Flow Drilling, Cast Material, Process Loads, Bore quality, Aluminium

* Corresponding author. Tel.: +49-231-755-5822; fax: +49-231-755-5141.

* E-mail address:author.
Corresponding hannich@isf.de
Tel.: +49-231-755-5822; fax: +49-231-755-5141.
E-mail address: hannich@isf.de
1877-7058 © 2017 The Authors. Published by Elsevier Ltd.
Peer-review©under
1877-7058 2017responsibility
The Authors. of the scientific
Published by Elseviercommittee
Ltd. of the International Conference on the Technology of
Plasticity .
Peer-review under responsibility of the scientific committee of the International Conference on the Technology of
Plasticity.

1877-7058 © 2017 The Authors. Published by Elsevier Ltd.

Peer-review under responsibility of the scientific committee of the International Conference on the Technology of Plasticity.
10.1016/j.proeng.2017.10.858
 D. Biermann et al. / Procedia Engineering 207 (2017) 956–961 957
2 D. Biermann et al. / Procedia Engineering 00 (2017) 000–000

1. Introduction

In its conventional application, flow drilling is a forming operation used to produce bushings in thin workpieces.
These bushings exceed the thickness of the workpiece in order to create detachable joints via a subsequent threading
operation and are used to elongate the usable depth of thread. The flow drilling process consists of different process
steps. The flow drilling tool is positioned in front of the workpiece and then moved along the tool axis. As soon as the
tool tip enters the workpiece, it is centred and due to the friction between the rotating tool and the workpiece, heat is
generated. Because of this heat, the workpiece material is softened. In the next process step, the conical region of the
tool penetrates the workpiece and the bore gets widened. Subsequently the cylindrical region defines the surface quality
of the bore wall. In a following process step, the material, which flows contrary to the feed direction, is machined or
formed regarding to the application of the tool collar.

Fig. 1. a) Process steps of front face flow drilling [1]; b) Used flow drilling tools; c) Via flow drilling generated bores

As far as this article is concerned, flow drilling is used to generate closed bores at the front face of profiles. This
opens up new potentials to join workpieces via a screw connection and makes it possible to avoid for example welding
operations. This application has been successfully tested on several materials, such as aluminium [2] or magnesium
wrought alloys [1]. The process steps does not vary from the conventional application (see figure 1 a). The presented
work however deals with the analysis of front face flow drilling regarding the aluminium cast alloy AlSi10Mg. The
low formability of aluminium cast alloys makes it difficult to obtain front face flow drilling to this material class
without any process adjustments. Regarding the current investigations, different process parameters as well as a pre-
heating of the tool were conducted. As a conclusion of this study suitable parameters, such as cutting speed v c, feed
velocity vf as well as initial tool temperatures T are given to create a stable flow drilling process of AlSi10Mg.

Nomenclature

dFD tool diameter vc cutting speed n rotational speed

vf feed velocity αFD point angle βFD cone angle
T initial tool temperature tW thickness of the workpiece t drilling depth
hT height of the tool tip hCo height of the conical part hCy height of the cylindrical part

2. Experimental setup

Used flow drilling tools are solid carbide tools without coating. The tools consist of different regions, which are
illustrated in figure 1 b). All tools have a diameter of dFD = 5.4 mm to enable a M6 thread size. The tool tip is the
shortest part with a height of hT = 0.5 mm in feed direction. The tool tip is constructed with a tip angle of α FD = 90°.
Following the tool tip, the conical region is located with a conical angle of βFD = 34°. The height of the conical region
measures hCo = 6 mm. The next part is the cylindrical region, which defines the surface quality of the bore wall. The
length of this region varies depending on the required drilling depth. In the case of this study the length is
hCy = 32.5 mm. The conical and the cylindrical region of the tool are not circular, but have a polygon shape. This
reduces the friction between tool and workpiece.
958 D. Biermann et al. / Procedia Engineering 207 (2017) 956–961
D. Biermann et al. / Procedia Engineering 00 (2017) 000–000 3

The chemical composition of AlSi10Mg alloy used for specimen preparation is given in table 1. The values were
determined by optical emission spectroscopy. The limiting values for alloying elements and impurities, respectively,
are also given as reference according to DIN EN 1706. All elements are in the range according to the standard [3].

Table 1. Chemical composition of aluminium AlSi10Mg alloy (wt.-%)

Al Mg Si Fe Cu Mn Ni Zn Pb Sn Ti Others
DIN EN 1706 Bal. 0.2-0.45 9-11 <0.55 <0.05 <0.45 <0.05 <0.1 <0.05 <0.05 <0.15 <0.15
AlSi10Mg Bal. 0.34 9.4 0.16 0.01 0.04 0.003 0.02 0.001 0.01 0.11 0.01

Figure 2 illustrates the microstructures of AlSi10Mg in longitudinal a) and cross section specimens b) before
manufacturing as light micrographs. AlSi10Mg shows a typical microstructure of a hypoeutectic Al-Si cast alloy with
acicular eutectic silicon (dark grey parts) distributed in the α-Al matrix (light grey parts) [4]. Furthermore, blow holes
can be observed in the matrix (black parts). The distribution of eutectic silicon in longitudinal and cross section
specimens is comparable. Area fractions of the phases were determined by means of digital image analysis methods
over thresholding in grayscale intensity images. The area fractions of eutectic silicon in longitudinal section differed
insignificantly (12.8% ± 0.4%) from cross section specimens (12.9% ± 0.4%).

Fig. 2. Microstructures of AlSi10Mg alloy before manufacturing; a) longitudinal section; b) cross section

All experiments were conducted on a CNC machining centre of the type Grob BZ 40. Details of the machining
centre are provided in figure 3 a). In order to measure the mechanical loads, a measuring device of the type 9255B
and a charge amplifier of the type 5070 from Kistler were used. It was possible to measure feed forces as well as
torques during the flow drilling experiments. To fix the workpieces, a machine vice was applied. The experimental
setup is shown in figure 3 b).

Fig. 3. a) Machining centre Grob BZ 40 CS; b) Experimental setup

Due to the low formability of the aluminium cast alloy at room temperature, adjustments of the process strategy in
form of a pre-heating of the tool were conducted. A portable induction system of the type Himmelwerk HU2000 Plus
was used. The inductor was placed near the machine vice within the machine room. To control the initial tool
temperatures, an infrared-pyrometer as well as a contact thermometer were assembled (figure 3). In a first step, the
tool was moved to the inductor and the required temperature was adjusted. In the next step, the tool was moved in
front of the workpiece and the flow drilling experiments were conducted.
 D. Biermann et al. / Procedia Engineering 207 (2017) 956–961 959
4 D. Biermann et al. / Procedia Engineering 00 (2017) 000–000

Another issue, which was analysed within this research, was the bore quality. In order to generate solid threads, it
is important, that the dimensions of the bore are fitting the requirements. Almost every bore produced via front face
flow drilling is oval-shaped to a certain extend. This is based on the fact, that the material can be formed differently
in radial direction regarding on the amount of surrounding material. Examples of generated bores via flow drilling are
presented in figure 1c. The workpiece materials as well as process parameters, such as feed velocity and cutting speed,
influence the bore quality. In order to quantify the bore quality, measurements of the bore diameter as well as the
roundness deviations were conducted via a 3D universal measuring machine of the type Zeiss Prismo Vast.
During the investigations the feed velocity vf as well as the initial tool temperature T were varied. Both process
parameters highly influence the result. The cutting speed vc was constant at vc = 120 m/min and the wall thickness of
the aluminium profiles was set to tW = 6 mm. Experiments with different initial tool temperatures from T min = 150°C
to Tmax = 300°C were conducted to support the formability of the aluminium cast alloy [5].

3. Results and discussion

In a first step, the results of the measurements of the process loads are explained. In figure 4 a representative
progress of the feed forces and the torques during the front face flow drilling of AlSi10Mg is depicted. In this case,
no pre-heating of the tool was applied. Analysing the feed forces first, an intense rise of the force can be noticed. This
is caused by the fact, that the tool starts to penetrate the workpiece and there is not much heat generated by friction.
After that, when the conical part penetrates the workpiece, enough heat is induced to soften the material and the feed
forces reduce to a stationary progress until the end of the process. The curve of the torque shows a slightly different
trend. The torque rises with higher friction surface as the tool moves along feed direction. As soon as the transition of
the conical and the cylindrical part immerged into the workpiece, a stationary progress similar to the feed forces can
be observed.

Fig. 4. Feed force and torque during front face flow drilling of AlSi10Mg

In figure 5 the maximal process loads of the flow drilling experiments are depicted dependent on the initial tool
temperature and feed velocities. At every combination of process parameters, four bores with two replications were
conducted and averaged. Analysing the feed forces, a slightly decreasing trend regarding higher initial tool
temperatures can be seen at every feed velocity. Due to the higher temperatures during the process and especially at
the beginning, the material is softened and the forces decrease. An increase of the feed velocity leads to rising feed
forces. This is based on the effect of a faster forming process and as a result a smaller amount of induced heat and less
material softening. A feed velocity of vf = 300 mm/min resulted in fractured bore walls, which made it impossible to
gain reliable process loads especially at high initial tool temperatures. Furthermore, the bore walls were damaged to
such a certain extent, that those bores could not be used for a threading process. Analysing the measured torques, a
continuous progress cannot be identified. It has to be considered, that the maximum of the feed force appears at the
beginning of the process (see fig. 3), while the maximum of the torque is reached when the conical part has penetrated
the workpiece. Because of this, the effect of the softening of the workpiece material caused by higher initial tool
960 D. Biermann et al. / Procedia Engineering 207 (2017) 956–961
D. Biermann et al. / Procedia Engineering 00 (2017) 000–000 5

temperatures is more distinctive analysing the feed forces than the torques. Another aspect, that can influence
especially the feed forces, is the allocation of silicon particles in the aluminium matrix (see fig. 2).

Fig. 5. Process loads dependent on the initial tool temperature and feed velocity

Using a pre-heating of the tool leads to better surfaces of the outer bore wall, as depicted in figure 6. The bore
walls showed fractures due to the low formability of the cast alloy, when conducting the experiments without a pre-
heating. The results of the bores generated with a pre-heated tool however showed a great effect regarding the quality
of the outer bore walls. But, as depicted, there are limits of the positive effect of a pre-heating. Initial tool temperatures
of T = 250°C and more result in fractured bore walls. Those fractures have to be investigated in further research via
the use of an infrared camera to get information about the temperatures within the process as a result of the initial tool
temperature and the heat induced by friction. The fractured bore walls make it impossible to generate threads and
therefore have to be avoided.

Fig. 6. Quality of the bore walls regarding the initial tool temperature

In order to analyse the bore quality, measurements of the bore diameter as well as the roundness deviations of four
bores per initial tool temperature have been conducted at a measuring depth of t M = 6 mm (figure 7). Bores, which
were generated at room temperature as well as at an initial tool temperature of T = 300°C could not be evaluated
because of the fractured bore walls. Best results regarding bore diameter and roundness deviations can be observed
 D. Biermann et al. / Procedia Engineering 207 (2017) 956–961 961
6 D. Biermann et al. / Procedia Engineering 00 (2017) 000–000

using an initial tool temperature of T = 200°C. The bore diameter fits the nominal tool diameter of dFD = 5.4 mm very
well and the roundness deviation is significantly low compared to those generated with other initial tool temperatures.

Fig. 7. Bore diameter and roundness deviations regarding the initial tool temperature

4. Summary and outlook

In this paper, front face flow drilling is investigated, which can be used to generate closed bores in thin profiles of
the aluminium cast alloy AlSi10Mg. Due to the insufficient formability of this material at room temperature,
experiments with a pre-heating of the tool were conducted. Results regarding the quality of the bore wall as well as
measurements of the diameter and roundness deviations show a great improvement of the generated bores. By using
a portable induction system it is possible to produce bores in an efficient way with a high process stability. The
temperatures must be adjusted carefully, because high temperatures cause the bores to fracture. The best results
regarding the bore quality, which includes closed bores as well as diameter and roundness deviations occur at an initial
tool temperature of T = 200°C. The mechanical loads were not strongly affected by the tool temperature. Only the
feed force showed a slightly decreasing trend.
In further research, the temperature during the flow drilling process should be investigated to get information about
the interaction of the initial tool temperature and the heat caused by friction between tool and workpiece. Another
important issue is the analysis of the microstructure of the subsurface zone. Influences on the structural conditions
and the micro hardness caused by the flow drilling process should be investigated. Also further adjustments towards
the process parameters could be made and a transfer of these results towards a magnesium cast alloy could be
investigated.

Acknowledgements

The presented investigations on front face flow drilling are part of the research project “Holistic development and
characterisation of an efficient manufacturing of detachable joints for aluminium and magnesium lightweight
materials” and are kindly funded by the German Research Foundation DFG (BI498/57, WA1672/11).

References

[1] D. Biermann, Y. Liu, Innovative Flow Drilling on Magnesium Wrought Alloy AZ31, Procedia CIRP, 18 (2014), p. 209-214.
[2] P. Wittke, F. Walther, Y. Liu, D. Biermann, Influence of the production process on the deformation and fatigue performance of friction drilled
internal threads in the aluminum alloy 6060, Materials Testing, 57 (2015) 4, p. 281-288.
[3] DIN EN 1706, Aluminium and aluminium alloys - Castings - Chemical composition and mechanical properties, Beuth-Verlag, Berlin, 2010.
[4] M.F. Ibrahim, E.M. Elgallad, S. Valtierra, H. W. Doty, F. H. Samuel, Metallurgical Parameters Controlling the Eutectic Silicon Characteristics
in Be-treated Al-Si-Mg Alloys, Materials 9, 78 (2016) p. 1-17.
[5] F. Ostermann, Anwendungstechnologie Aluminium, third edition, Springer-Verlag Berlin Heidelberg, p. 297-307, 2014.