Modeling and analysis of roundness error in friction drilling of aluminum silicon carbide metal matrix composite

Friction drilling is a newer nontraditional hole-making chipless process, which is used to make holes in materials that are used in aerospace, automotive, commercial and industrial products, electronic packaging, and thermal management. In friction drilling, a rotating conical tool is applied to penetrate work-material and create a hole in single step. In this study, comprehensive analysis on friction drilling of Al/SiCp metal matrix composites is carried out. This article discusses the roundness (hole diameter accuracy) errors on dry friction-drilled holes. The parameters considered for the experiment are: the composition of workpiece, workpiece thickness, spindle speed, and feed rate. The effect of parameters on roundness errors is analyzed using experimental design matrix and empirical relation between the process parameters and roundness error is established using response surface methodology. Analysis of variance is used for analyzing the results. The influences of individual input process parameters on roundness error are analyzed and presented in this study.