Finite-element simulation and validation of material flow in thermal drilling process

Galvanized steel is broadly employed in metal roofing, air conditioning duct, support beams, construction materials, and domestic appliances, etc. In conventional drilling method has limitations such as asymmetrical holes, as well as formation of crack inside the hole made in sheet metal. This problem was entirely exterminated in thermal drilling (TD) process. In the course of TD process, the high temperature was developed due to rotational and feed rate of thermal drill into the workpiece. Owing to this reason, the thermal drill pierces workpiece effortlessly. However, in this process, workpiece deformation is very high; therefore, finite-element simulation is used to study the material flow which is challenging in experimental method. According to finite-element method (FEM), the finite-element analysis of TD process was conducted by the DEFORM-3D simulation software. The aim of this study is to conduct an experimental investigation of TD process on galvanized steel (GS), and then, it is compared to numerical results obtained from the FEM. Between experimental and FEM simulation of TD process, a good relationship was found.