Design of Conical Channel in Joining of AA7075/AZ91 Materials by Mechanical Locking Method

Year 2023, , 128 - 134, 06.07.2023

Serdar Mercan

https://doi.org/10.46460/ijiea.1209427

Abstract

ABSTRACT
Material types with different chemical and physical properties are employed by being joined in industrial applications. The major objective is to generate high-performance prochannels by bringing outstanding properties of materials together. Many conventional methods, primarily welding method such as casting, adhesion, rivet weld, and bolts are employed in joining procedures. Among the joining methods, mechanical locking, a novel and ecologically friendly method, stands out as a successful method, particularly when joining dissimilar metal types. Within the scope of this study, the optimization of the channel geometry was performed on the AZ91 mold part, out of AA7075/AZ91 material pairs joined by using the mechanical locking method. The channel design was paid attention to ensure that it do not adversely affect the stress values and facilitates material flow. Fixed joint angle and fixed channel depth were used in accordance with the data received from previous research results and employed in the analysis. The analyses were completed using the finite element method and the Static Structural Module of the Workbench 18.2 version of the ANSYS software. The whole study was carried out on 3D geometric models. As a result, it was determined that the mechanical properties of the samples joined by MLM significantly changed depending on the channel design. The mechanical properties of the joint improved by roughly 3% with the optimal joint design, while the joint design that will facilitate material flow was achieved.

Keywords

Mechanical Properties, AA7075, AZ91, finite element method (FEM), mechanical locking method (MLM)

Mekanik Kilitleme Yöntemi ile Birleştirilen AA7075/AZ91 Malzemelerin Konik Kanal Tasarımı

Abstract

Özet
Endüstriyel uygulamalarda, farklı kimyasal ve fiziksel özelliklere sahip malzeme türleri birleştirilerek kullanılmaktadır. Temel amaç malzemelerin üstün özelliklerini bir araya getirerek, yüksek performanslı ürünler elde edilmesidir. Birleştirme işlemlerinde kaynak yöntemi başta olmak üzere döküm, yapıştırma, perçin ve civata ile birleştirme gibi geleneksel birçok metod kullanılmaktadır. Birleştirme yöntemleri arasında yeni ve çevreci bir yöntem olan mekanik kilitleme yöntemi de özellikle farklı metal türlerinin birleştirilmesinde başarılı bir yöntem olarak öne çıkmaktadır. Bu çalışma kapsamında, mekanik kilitleme yöntemi ile birleştirilen AA7075/AZ91 malzeme çiftlerinden kalıp parçası AZ91 üzerindeki, kanal geometrisinin optimizasyonu yapılmıştır. Kanal tasarımının gerilme değerlerini olumsuz etkilemeden, ve malzeme akışını kolaylaşıracak biçimde olmasına dikkat edilmiştir. Analizlerde daha önce yapılan araştırma sonuçlarından elde edilen verilere uygun olarak belirlenen sabit bağlantı açısı, sabit kanal derinliği kullanılmıştır. Analizler sonlu elemanlar yöntemini kullanan ANSYS paket programının Workbench 18.2 sürümü, Static Structural Modülü kullanılarak tamamlanmıştır. Tüm çalışma 3 boyutlu geometrik modeler üzerinden gerçekleştirilmiştir. Sonuçta MLM ile birleştirilen numunelerde kanal tasarımına bağlı olarak mekanik özelliklerin önemli oranda değiştiği tespit edilmiştir. Optimum bağlantı tasarımı ile bağlantı mekanik özellikleri yaklaşık %3 oranında artarken, malzeme akışını kolaylaştıracak bağlantı tasarımı elde edilmiştir.

Keywords

AA7075, AZ91, sonlu elemanlar yöntemi (FEM), mekanik kilitleme yöntemi (MLM), mekanik özellikler

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