Effects of Residual Stresses on the Fatigue Lifetimes of Self-Piercing Riveted Joints of AZ31 Mg Alloy and Al5052 Al Alloy Sheets

During the self-piercing riveting (SPR) process, residual stress develops due to the high plastic deformation of the sheet materials. In this study, the effect of the residual stress on the fatigue lifetime of SPR joints with dissimilar magnesium AZ31 alloy and aluminum Al5052 alloy sheets was evaluated. The residual stress distribution was derived through a simulation of the SPR process by the FEA (finite element analysis). The measured values by the X-ray diffraction technique confirmed that the validity of the simulation has a maximum error of 17.2% with the experimental results. The fatigue strength of the SPR joint was evaluated at various loading angles using tensile-shear and cross-shaped specimens. It was found that the compressive residual stresses of the joint reduce the stress amplitude by 13% at 106 cycles lifetime, resulting in extension of its lifetime to approximately 3.4 million cycles from 106 cycles lifetime. Finally, it was confirmed that the fatigue life of SPR joints was appropriately predicted within a factor of three using the relationship between the fatigue life and the equivalent stress intensity factor. The fatigue resistance of the magnesium AZ31 alloy on the upper sheet was found to govern fatigue lifetimes of SPR joints of dissimilar magnesium AZ31 alloy sheets.

ANALISIS KOEFISIEN PENGURANGAN TATAL (CHIP REDUCTION COEFFICIENT) PADA PEMESINAN BUBUT MAGNESIUM AZ31 MENGGUNAKAN PAHAT PUTAR

Coefficient reduction chip atau pengurangan tatap dianalisa menggunakan Metode Anova untuk menentukan pengaruh dari parameter input untuk setiap variasi eksperimen pada proses permesinan, sekaligus juga menentukan persentase pengaruh parameter individual. Metode Taguchi dipilih untuk mengurangi jumlah total dari percobaan yang dilakukan dan menghilangkan aspek yang tidak perlu dipertahankan, mengurangi biaya percobaan, sederhana dan mendapatkan hasil yang presisi. Penelitian ini bertujuan untuk menganalisa koefisien pengurangan tatal yang terjadi pada saat pemesinan menggunakan material paduan magnesium AZ3. Pada penelitian ini, proses pemesinan dilakukan menggunakan mesin bubut dengan jenis pahat berputar, yang mana pahat yang digunakan adalah pahat karbida jenis round insert. Sementara itu metode pengujian yang diterapkan adalah menggunakan Metode Taguchi dan ANOVA. Sementara itu, diameter benda kerja digunakan sebesar 35 mm dan Panjang 100 mm, kedalaman potong 1 mm dan kecepatan potong 80, 120, 160 mm/min, kadar pemakanan 0,10 0,15 0,20 mm/rev, kecepatan putaran pahat 50, 80, 120 rpm. Hasil dari penelitian ini menunjukan bahwan nilai koefisian pengurangan tatal terendah sebesar adalah 1,44, yang mana diperoleh pada parameter kecepatan potong 80 mm/min, kedalaman potong 1 mm, kadar pemakanan 0,10 mm/rev dan kecepatan putaran pahat 50 rpm. Dari semua faktor yang dianalisa, didapati bahwa faktor yang berpengaruh signifikan yaitu kecepatan potong da kadar pemakanan.

MODELING AND OPTIMIZATION OF HOLE ACCURACY AND DRILLING TIME IN MAGNESIUM AZ31 PLATE

Owing to the advancement in the field of materials, different range of grades have been developed. The machinability examination of these newer grades must be carried out for future applications. One such newer grade of magnesium with AZ31 is deemed for study during the drilling process. The independent parameters considered are spindle speed (SS), feed rate (FR) and drill bit diameter (DBD). The dependent parameters considered are burr height (BH), burr thickness (BT), drilling time (DT) and surface roughness (SR). Improving hole accuracy is essential for manufacturing superior products, which is discussed in this work. At the same time, the machining time has also to be minimized to increase the production rate. With these objectives, the experimental investigation is made. Further, an analytical model for predicting the responses is developed; later, optimization is carried out to obtain the desired responses through the desirability function approach. The multi-objective optimization suggests the SS of 1100[Formula: see text]rpm, the FR of 0.198[Formula: see text]mm/rev., and the DBD of 6[Formula: see text]mm for reducing the entire dependent is reckoned.