The main purpose of this research is to study the optimal process parameters for thermal friction drilling process on AISI 304 stainless steel. The experiments were conducted based on Taguchi experimental design method, and the multiple performance characteristics correlated with the resultant axial force, radial force, hole diameter dimensional error, roundness error, and bushing length, were investigated by fuzzy logic technique. The significant process parameters that most intensively affected the multiple performance characteristics and the optimal combination levels of process parameters were determined through the analysis of variance and the response graph. A test rig was manufactured at Shoman Company ‒ Egypt to perform the experimental work, and the tools were offered by Flowdrill Company ‒ Germany. Experimental results confirm that this approach is simple, effective and efficient for simultaneous optimization of multiple quality characteristics in thermal friction drilling process, as the bushing length produced is more than five times the workpiece thickness.

[1]Ross, P. 1988 Taguchi techniques for quality engineering: loss function, orthogonal experiments, parameter and tolerance design. second edition, McGraw-Hill book Co-Singapore Copyright © 1996, ISBN 0-07-114663-6.
[2]Taguchi, G., Chowdhury, S., and Wu, Y. 2005 Taguchi quality engineering handbook. ISBN 0-471-41334-8, John Wiely & Sons, Inc.
[3]Hsiang, S., and Lin Y. 2009 Optimization of the extrusion process for Magnesium alloy sheets using the fuzzy based Taguchi method. the Arabian journal for science and engineering, volume 34, number 1c.
[4]Puri, Y., and Deshpande, N. 2004 Simultaneous optimization of multiple quality characteristics of WEDM based on fuzzy logic and Taguchi technique. Proceedings of the Fifth Asia Pacific Industrial Engineering and Management Systems Conference.
[5]Yen, J., and Langari, R. 1999 Fuzzy Logic: intelligence, control, and information. Prentice hall, upper saddle river, New Jersey 07458, ISBN: 0-13-525817-0.
[6]Wu, C., Fang, T., and Kuo, C. 2014 Atomistic simulation of nanodrilling mechanics and mechanism on Cu substrates. Appl. Phys. A, Materials science and processing, DOI 10.1007/s00339-014-8732-5.
[7]Ku, W., Hung, C., Lee, S., and Chow, H. 2010 Optimization in thermal friction drilling for SUS 304 stainless steel. Springer-Verlag London Limited 2010, Int. J. Adv. Manuf. Technol. 53:935–944, DOI 10.1007/s00170-010-2899-5.
[8]Miller, S., Tao, J., and Shih, A. 2005 Microstructural alterations associated with friction drilling of steel, aluminum, and titanium. JMEPEG 14:647-653 ©ASM International, DOI: 10.1361/105994905X645581 0599495.
[9]Miller, S., Tao, J., and Shih, A. 2005 Friction drilling of cast metals. International Journal of Machine Tools & Manufacture 46 1526–1535, DOI 10.1016/j.ijmachtools. 2005.09.003.
[10]Lee, S., Chow, H., and Yan, B. 2007 Friction drilling of IN-713LC cast superalloy. Materials and Manufacturing Processes, 22: 893–897, 2007, Copyright © Taylor & Francis Group, LLC, ISSN: 1042-6914 print/1532-2475 online, DOI: 10.1080/10426910701451697.
[11]Lee, S., Chow, H., Huang, F., and Yan, B. 2008 Friction drilling of austenitic stainless steel by uncoated and PVD AlCrN- and TiAlN-coated tungsten carbide tools. International Journal of Machine Tools & Manufacture 49, 0890-6955/$, Crown Copyright © Published by Elsevier Ltd., DOI: 10.1016/j.ijmachtools.2008.07.012.
[12]Ku, W., Chow, H., Lin, Y., Wang, D., and Yang, L. 2010 Optimization of thermal friction drilling using grey relational analysis. eAdvanced Materials Research Vols. 154-155 pp 1726-1738, Copyright © Trans. Tech. Publications, Switzerland DOI: 10.4028/www.scientific.net/AMR.154155. 1726.
[13]Tsai, P., Gilmour, S., and Mead, R. 2000 Projective three-level main-effects designs robust to model uncertainty. Biometrika, 87, 2 pp. 467-475 © Biometrika Trust printed in Great Britain.

@article{Sara04021006,
title = " Optimization of Thermal Friction Drilling Process Based on Taguchi Method and Fuzzy Logic Technique ",
journal = "International Journal of Science and Engineering Applications (IJSEA)",
volume = "4",
number = "2",
pages = "54 - 59",
year = "2015",
author = " Sara A. El-Bahloul,Hazem E. El-Shourbagy ,Tawfik T. El-Midany ",
}