Polyoxymethylene (POM), as an energy‐saving material, is widely applied in the manufacturing field. Yet, research on the rectangular clinching process between metal and POM sheets is still lacking. In this paper, the rectangular clinching process for POM and Al5052‐H32 plates was investigated. The feasibility of the metal–polymer hybrid component had been analyzed in terms of diverse forming forces and diverse joint layout angles, respectively. The mechanical characteristics were appraised by the lap‐shear test. The failure modes of rectangular clinched joints produced under diverse forming conditions had also been analyzed. The results showed that the optimal forming force of rectangular clinched joints was 14 kN, in which the lap‐shear strength was 1090 N. Furthermore, the rectangular clinched joints produced under the joint layout angle of 90° could withstand the maximum lap‐shear load (1415 N) under the optimal forming force. The failure mode was the separation of two plates and the fracture of the bridge structures.
In order to discuss the influence of the stress ratio on the corrosion fatigue life of high‐strength steel wires, a theoretical and experimental investigation was conducted on corroded steel wires at three different stress ratios (R = 0.1, 0.3, and 0.5) under axial tensile fatigue loading. Different S‐N curves of corroded steel wires were regressed from test data. The stress method based on eight mean stress correction models, the strain energy method, and the facture mechanics method considering environmental corrosion and crack closure were proposed to estimate the fatigue life. Preliminary results show that corrosion can reduce the ultimate strength, the yield strength, and the fatigue life. There is a negative correlation between corrosion fatigue life and stress ratio. When R > 0, fatigue life predicted results by using the Morrow and Marin models in the stress method are more efficient and accurate than other models. Likewise, the Zheng model in the fracture mechanics method is in better agreement with test results. The error and scatter of the strain energy method are relatively large. Therefore, the Morrow, Marin, and Zheng models are more suitable to predict the corrosion fatigue life of high‐strength steel wires under different stress ratios.
The advantages of well-distributed material flow, easy demolding, and good mechanical interlock structure of the extensible die provide the possibility to be widely used in joining lightweight components. In order to explore the differences in the mechanical properties of the joints produced by different dies, the mechanical behavior of the clinched joints made by the fixed die and extensible dies of 2, 3, and 4 movable segments was investigated in the present study. The process of forming evolution, geometric characterization, failure mode, static strength, joint stiffness, and energy absorption of the dissimilar joints were studied by experimental method. In the clinching process, the neck thickness of joints made by extensible dies can be enlarged by the sliding outward of the movable segments compared with those produced by fixed dies. The failure mode of all clinched joints in this paper is neck fracture. The clinched joints produced by extensible dies of 3 movable segments have the highest static strength in both static tensile and shear tests among the dissimilar joints, which values are 1239.41 and 1259.80 N, respectively. Shearing strength of the joints performed by the extensible dies with 2, 3, and 4 movable segments was increased by 9.84%, 10.09%, and 9.40%, and the tensile strength of those clinched joints was increased by 16.27%, 20.31%, and 14.34% than that of the joints produced by the fixed dies. Experimental have proved that the number of movable segments on the extensible dies has a limited effect on the joint stiffness, tensile strength, and energy absorption of the clinched joints in the cross-lap-tensile test, while it has great effect on the stiffness and energy absorption of the clinched joints in the single-lap-shear test.
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