As a novel method in drilling machining process, friction drilling is a non-conventional hole making process that uses the heat generated from friction between the rotating conical tool and the workpiece to soften, penetrate and form a hole in a thin work-piece. The process involves forcing a rotating, pointed tool through a sheet metal workpiece which used to generate heat by friction to soften and generate the required hole. In this search, the selected rotational spindle speeds were 500 rpm, 800 rpm, 1250 rpm, and 2000 rpm as well as the selected feed rates were 0.04m/min, 0.06m/min, 0.10m/min, and 0.13m/min. The tool was designed with 24°, 36°, 48°, and 60° conical angles. Proper experimental design using Taguchi approach was developed in this work. The effect of rotational spindle speed, feed rates and tool conical angle on the bossing height, bushing height, hole diameter, base diameter, total bushing height and the bushing wall thickness were analyzed.