Thermal friction drilling is a novel nontraditional hole-making process. A rotating conical tool is applied to penetrate a hole and create a bushing in a single step without generating chips, providing a more solid connection for attachment than attempting to thread the original sheet. The amazing applications of thermal friction drilling in different industrial fields will lead to new era of joining process for different work materials, especially in the sheet metal applications. The aim of this work is to review the state of the art for researches performed on the friction drilling process as well as its applications considering its advantages and limitations. Thereby, to highlight the important and critical issues that should be tackled and investigated by researchers in the near future such as studying the optimal machining parameters of such process and evaluating their effects on the multiple performance characteristics.

In this study, a comparison between ultrasonic-assisted drilling (UAD) and conventional drilling (CD) is presented under different feed rates using thrust force, torque, and hole geometrical errors as output responses. The experiments were done on plates of Inconel 601 (nickel-based superalloy), which is classified as a difficult-to-cut alloy due to its high Nickel content (60%), high hardness (43 HRC), and low thermal conductivity. The experiments were performed using DMG Mori Ultrasonic 20 linear, which is equipped with ultrasonic tool holderoscillating at 20 kHz with 7 μm amplitude. A coated carbide single margin twist drill had been used in the experiments. Full factorial design of experiments approach was employed, and the results had been statistically analyzed to find the most significant factor affecting the process responses. The results showed that the ultrasonic assistance had reduced the thrust force, and torque compared to conventional drilling (CD). Also, a reduction in holecylindricity error was detectedduring UAD, whichimprovesthe hole quality. In case of UAD, twist drills did not suffer from a physical wear, however notch wear was observed in CD drills. Chip morphology was also studied. Short segmented chips were obtained when using UAD which improved chip evacuation and reduced the chance of chip jamming in the drill flutes.

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The main purpose of this research paper is to improve the quality of the friction-drilled holes and formed thread by investigating the influence of the input working parameters that have not been investigated yet on the quality of the produced bores. Due to lack of research related to the hardness macro- and microstructure of formed threads, experiments were conducted to investigate these important issues. Finally, a tension test was performed to compare the performance of the form tapped thread with the conventionally cut thread. The experiments were conducted on difficult-to-cut material AISI 304 stainless steel workpieces with (2 and 3 mm) wall thicknesses. Tungsten carbide friction drills with diameters (Ø9.2, Ø7.3, and Ø4.5 mm) were used to perform the experiments. The effects of the ratio of workpiece thickness (t) to tool diameter (dT), rotational speed (N), and feed speed (f) on the hole diametral oversize (U), cylindricity error, and collar height were studied. The analysis of variance (ANOVA) showed that the t/d ratio was the most significant factor affecting the mean cylindricity error and the collar height. By comparing the performance of the three tools, it was noticeable that the friction drill Ø7.3 realized better results in terms of mean hole diametral oversize and mean cylindricity error. The elevated temperature associated with high plastic deformation during the processes resulting in fine grains with high hardness values were observed at the heat-affected zone. The longer effective thread length of the formed thread realized higher strength values than the cut thread. Graphical abstract