Alternative sheet metal fixing technic and dynamic analysis of drum related to this technic

The machines that are in our living area must be esthetic with their functionality. So, industrial design happened more important in these days. Well designed productions about industrial design, have advantages in competitive environment. But, at the same time, productions must be cheaper for more sales in competitive environment. Alternative raw material usage is common for machines that have more perceived quality and less prices. For example, coated sheet metal usage is more than stainless sheet metal usage because of its price, although stainless have more perceived quality. Different materials can be used with same construction due to production requirements, visual and cost differences for demands of customers. Part strength and producibility are affected, if you use different materials that have different mechanical properties with same production tools. So, construction must be checked about producibility and reliability. This study includes clinching strengths of a tumble dryer's drum's different sheet metals that clinched with same tools at same press parameters. The sheet metal that used at die side for all tests is DX51D+AZ150 due to EN10346:2009 and its thickness is 1.5mm. The sheet metals that used at punch side are ferritic stainless steel due to AISI 430, DX52D+Z275 due to EN10346:2009, HX340LAD+AZ150 due to EN10346:2009, and their thickness is 0.5mm for all samples. Clinching tool have 8mm point diameter and 0.8 depths at die side and 5.6mm punch diameter at punch side. Press applied 54-55kN when clinching that includes hold down force. Hold down force applied 4176N. Clinched materials total thickness became 0.6mm for all test. In the study, 6 and 3 connections that are without any additional materials between flange and drum rear part were analyzed under 16 kg load condition. Maximum normal force occured 49.3 N for one connection with design that have 6 connections. Maximum shear force occurred 46.9 N for one connection with design that have 6 connections. Maximum normal force occured 98.5 N for one connection with design that have 3 connections. Maximum shear force occurred 93.8 N for one connection with design that have 3 connections. Clinched sheet metals samples prepared for share and pull force tests and test applied to all samples. And this condition created with CAE and anlysed. According to analysis and test results, clinching that applied to stainless steel at punch side have max. share and pull strength forces in examined materials. And H340LAD+AZ150 material is more strength than DX52D+Z275 material. As a result, construction must be designed due to DX52D+Z275 material, if same tools, production parameters and design are used. The purpose of this study is to detect connection strength of two sheet metal's clinching that clinched with different punch side material, same clinching tools at same press parameters with analysis and tests. In conclusion; the strength values were obtained with 34% - 59% deviation due to test results that are tested with coated drum rear part. This value was obtained with 1% -2% deviation due to test results that is tested with AISI 430 drum rear part. In addition, the test results vary from 12% to 44% based on the average of the test results. Therefore, the design should be done considering these ratios. According to the analysis and test results for the current design, both the shear strength and the normal strength are suitable. Used materials affect clinching strength if materials clinched with same tools at same production parameters. Normal and share tests used for defining the strength of clinching. Due to test results, clinching that applied to stainless steel at punch side have max. share and pull strength forces in examined materials. And H340LAD+AZ150 material is more strength than DX52D+Z275 material. New design must be checked about producibility and reliability, due to DX52D+Z275 material usage, if same tools, production parameters and design are used.