Tapping and alternative material analyzing of thin wall CM22NBK material flowdrill process

There are different methods of tapping on surfaces of materials that have thin wall. One of these methods is flowdrill process. In the facility, especially during the production process of coach busses? front frame, flowdrill is applied to three different areas. It is not % 100 realized on other frames because it is a new production technique in the facility. Flowdrill process is applied only to CM22NBK profiles which have 3 mm thicknesses in production lines. From this point of view, it is required to compare and evaluate the results when flowdrill process is applied to St37-2 and S460MC profiles that are used in the production more often than CM22NBK profiles. Method of flowdrill process is examined essentially and it is analyzed likely problems during bushing operations. After bushing operations, tapping operation is applied to the test samples and bushing formed samples are sent to magnetic particular test. Afterwards, hardness around the flow drill points is examined and then whole test samples are fixed to the tensile test instrument and strength values are analyzed. vii Same tests are applied to S460MC profiles which have 2 mm thicknesses and all test results are compared with each other before coming to a conclusion. Finally, the special sample with inserted bolt into M8 thread is fixed to the tensile test instrument all over again and the force that is teared off the bolt from material is compared with each other. Consequently, after these tests, an alternative material S460MC which have thickness 2 mm is proposed instead of CM22NBK which has a frequent usage in production and calculated weight and cost gains. The other gain that will be calculated according to process changing which were chosen on the frame from welding nut and plate by flowdrill process. Key Words : Flowdrill, flowtapping, form bushing, drilling