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Updated: Oct 16, 2025

Knowledge Based Cloud FE Simulation of Sheet Metal Forming Processes
Published on: December 13, 2016
Finite Element and Finite Volume Modelling of Friction Drilling HSLA Steel under Experimental Comparison
Bernd-Arno Behrens1, Klaus Dröder2, André Hürkamp2
1Institute of Metal Forming and Forming Machines, Leibniz Universität Hannover, 30823 Garbsen, Germany.
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.
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