Strength Prediction Model of Aluminum Alloy Clinched Joints Formed With Segmental Mandrel
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摘要: 采用Box-behnken design(BBD)实验设计法,开展铝合金压印接头的工艺试验研究。试验过程选用了5182、5052和6061这3种铝合金薄板,建立了以冲压力、板材厚度、板材硬度为影响因素,以失效载荷为响应值的多元回归模型,并进行了试验验证。结果表明:建立的多元回归模型可以预测铝合金压印接头的拉剪失效载荷,最大误差为17.7%,其误差在工程应用范围内较小;且方差分析表明,各因素对失效载荷影响程度大小的顺序为冲压力、板材硬度、板材厚度;压印接头的失效载荷随冲压力的增大呈先增大后减小的趋势,随板材厚度的增大呈先减小后增大的趋势,板材硬度对接头失效载荷的影响呈正线性相关性。Abstract: Based on the Box-behnken design (BBD) test design method, the mechanical properties analysis of aluminum alloy clinched joints was carried out. Three kinds of aluminum alloy sheets 5182、5052 and 6061 were used in the test. A multivariate regression model with punching pressure, sheet thickness and sheet hardness as the influence factors and failure load as response value was established, and the model was verified via experiments. The results show that the multivariate regression model can accurately predict the tension-shear failure load of aluminum alloy clinched joints in a certain range of processing parameters, the maximum error is 17.7%, and the error is small in application. Variance analysis shows that the impact on the failure load is the largest in the order of punching pressure, followed by the sheet hardness and the sheet thickness. The failure load of the clinched joint firstly increases and then decreases with the increasing of punching pressure, and firstly decreases and then increases with the increasing of sheet thickness. The influence of the sheet hardness on the failure load of joint is positively linear correlation.
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Key words:
- clinching /
- response surface method /
- regression model /
- prediction mode
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表 1 试验因素及水平设计
Table 1. Experimental factors and level design
因素编码值 冲压力
X1/kN板材硬度
X2/HBR板材厚度
X2/mm−1 32.2 18.6 1 0 38.4 31.0 1.5 1 48.7 55.3 2 表 2 实验方案及结果
Table 2. Experimental program and results
组号 冲压力
X1/kN板材硬度
X2/HRB板材厚度
X3/mm失效载荷
Y/kN1 32.2 18.6 1.5 1.5 2 48.7 18.6 1.5 2.1 3 32.2 55.3 1.5 0.33 4 48.7 55.3 1.5 3.19 5 32.2 31 1 1.7 6 48.7 31 1 2.51 7 32.2 31 2 2.1 8 48.7 31 2 2.21 9 38.4 18.6 1 2 10 38.4 55.3 1 2.87 11 38.4 18.6 2 2.05 12 38.4 55.3 2 3.55 13 38.4 31 1.5 2.15 14 38.4 31 1.5 2.13 15 38.4 31 1.5 2.12 表 3 失效载荷响应面回归模型的方差分析
Table 3. ANOVA of the response surface regression model for failure loads
因素 平方和 自由度 均方差 F值 Prob>F 模型 5.85 6 0.98 4.30 0.0310 X1 3.09 1 3.09 13.61 0.0061 X2 1.00 1 1.00 4.41 0.0689 X3 0.086 1 0.086 0.38 0.5549 X1X2 1.29 1 1.29 5.70 0.0440 X1 2 1.11 1 1.11 4.89 0.0579 X3 2 0.72 1 0.72 3.18 0.1124 失拟项 1.81 6 0.30 1295.78 0.0008 表 4 验证实验结果
Table 4. Results of validation experiments
组号 基板材料 冲压力/kN 板材硬度/HRB 板材厚度/mm 预测值/kN 试验均值/kN 相对误差/% 1 5182 44.3 18.6 2.0 2.499 2.141 16.7 2 1420 56.1 62.0 1.5 3.374 2.867 17.7 -
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