Multiphysics SPH simulation of flow drilling process

Flow drilling is an alternative drilling solution for metal plates up to several centimeters. Using a conical tool, the process combines high rotation speed and high pressure to initiate friction and heat up the plate material locally in contact with the tool. As a consequence, the heated material has its mechanical characteristics reduced and is subjected to a very large plastic deformation. The surplus of matter is not wasted but is shaped into a collar above the metal plate and a socket below. These bulges induce a local additional thickness enabling a direct threading without added parts (bolt...).