الفهرس 
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Abstract
This thesis presents a study about thermal friction drilling process, which is a nontraditional hole-making method that uses the heat generated from friction between a rotating conical tool and the workpiece to soften and penetrate the workpiece material and generate a hole. The main purpose of this work is to present the optimization of the thermal friction drilling process parameters; namely, tool diameter, friction angle, friction contact area ratio, feed rate, and rotational speed, on AISI 304 stainless steel, by using uncoated tungsten carbide tools. 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 response table and the analysis of variance. A test rig was designed, and manufactured at Shoman Company ‒ Egypt to perform the experimental work, and the tools were offered by Flowdrill Company ‒ Netherlands. MATLAB, version (V7.14.0.739) release (R2012a), is used as the programming language with the help of graphical user interface, visual aids, and Fuzzy Logic toolboxes. The optimal process parameters combination will achieved at tool diameter = 9.2 mm, friction angle = 30o, friction contact area ratio = 50 %, feed rate = 60 mm/min, and rotational speed = 2500 rpm at workpiece thickness = 1, 2, and 3 mm for the proposed experimental levels. A confirmation test is performed to verify this result and proved its success. Experimental results confirm that this approach is simple, effective and efficient for simultaneous optimization of multiple quality characteristics in thermal friction drilling process. Thus, the performance of thermal friction drilling process on difficult-to-machine materials such as stainless steel would be ascertained to fit requirements of modern industrial applications.