Friction drilling as an alternative to conventional drilling in HVAC production
Johnson Controls is a leading manufacturer of heating and air conditioning systems (HVAC). During the production process, the company encountered issues caused by a complex drilling process. Metal chips in the AC units caused disruptions and affected product quality.
To solve these issues structurally, Johnson Controls looked for an alternative to conventional drilling. Friction drilling emerged as a chipless solution.
During the search for a robust solution, Johnson Controls was informed by the BLM Group about the possibilities of chipless friction drilling. BLM Group designs and builds, among other things, tube lasers and bending machines for processing tubes, wire, and sheet material.
After this introduction, Johnson Controls thoroughly investigated the possibilities of replacing conventional drilling with friction drilling. The objective was a chip-free production process with stable and repeatable results.
Johnson Controls defined clear requirements for the solution. Production needed to be chipless, and the partner had to provide support and ensure sustainability. Flowdrill developed customer-specific friction drilling tools for the Johnson Controls application. Thanks to experience and technical support, a suitable solution was realized.
With 40 years of experience in friction drilling, Flowdrill had the expertise to deliver customized tools. This gave Johnson Controls confidence to implement the process.
For Johnson Controls, reducing chips was the primary requirement. Additionally, the holes had to be accurate and consistent so they would be suitable for brazing in HVAC cooling units.
Test samples were produced and then evaluated by Johnson Controls for dimensional accuracy and quality. After approval, production started with the new assembly line where friction drilling was applied.
After implementation, the process was positively received by the production team. By changing tools where necessary and maintaining consistent hole quality, the earlier problems with chips and varying hole diameters disappeared. This resulted in less rework and a more efficient production process.
“The Flowdrill tool itself proved impressive, but it was the exceptional Flowdrill team that left a lasting impression.”
– Wesley Jones
By integrating friction drilling into the production process, Johnson Controls improved process stability. Problems caused by chips in HVAC systems were eliminated. Efficiency increased and the need for corrective work decreased.
Johnson Controls continues its collaboration with Flowdrill to support future optimizations.
