Finite Element Analysis of Sheet Metal Bending Operation using Ansys Workbench
Objective: Compare the Finite Element Analysis results obtained by using different materials for Sheet Metal in a Sheet Metal Bending Operation and write a detailed report explaining the results obtained.
Question:
Run the analysis for the material :
Case 1:Aluminium Alloy 1199( mentioned in the course video),Copper Alloy NL and Magnesium Alloy NL. Find out the Equivalent stress, Equivalent elastic strain and Total Deformation in Y direction and compare the results for the three materials.
Case 2:With the material as Aluminium Alloy, change the friction coefficient to 0.19 and run the analysis as mentioned in Case 1. Compare the results with that in case 1.
Case 3: Refine the mesh on the plate such that it doesn't cross the academic limit. With Aluminium alloy as material, run the analysis as in Case 1 and compare the results.
Case Setup and Execution:
Model:
Boundary Conditions:
Material: Structural Steel for Die and Punch.
Analysis Settings:
Displacement: Displacements has been applied as shown below.
Case-1: Compare Results of Aluminum alloy 1199, Copper Alloy NL and Magnesium Alloy NL as sheet materials.
Boundary Conditions:
Contacts: Contacts has been applied as shown below.
Mesh:
Body Sizing: Punch and Die:- Size of element- 4mm.
Body Sizing: Sheet:- Size of element- 1mm.
Case-1a: Aluminum alloy 1199.
Material: Aluminum Alloy 1199 for Sheet.
Results:
Equivalent Stress:
Equivalent Elastic Strain:
Directional Deformation: Y-axis.
Equivalent Stress of Sheet:
Case-1b: Copper Alloy NL.
Material: Copper Alloy NL for Sheet.
Results:
Equivalent Stress:
Equivalent Elastic Strain:
Directional Deformation: Y-axis.
Equivalent Stress of Sheet:
Case-1c: Magnesium Alloy NL.
Material: Magnesium Alloy NL for Sheet.
Results:
Equivalent Stress:
Equivalent Elastic Strain:
Directional Deformation: Y-axis.
Equivalent Stress of Sheet:
Results Comparison:
| CASE-1 | Directional Deformation: Y-axis | Equivalent Elastic Strain | Equivalent Stress of Sheet | |||
| mm | * | Mpa | ||||
| Min. | Max. | Min. | Max. | Min. | Max. | |
| Aluminum Alloy 1199 | -13.979 | 3.7109 | 6.13E-14 | 0.22189 | 1.47E-05 | 441.46 |
| Copper Alloy NL | -13.551 | 3.7174 | 3.86E-17 | 0.25133 | 2.71E-06 | 444.71 |
| Magnesium Alloy NL | -13.545 | 3.7633 | 8.15E-15 | 0.57266 | 5.84E-05 | 326.73 |
- Max. Directional deformation in Y-axis is highest in Magnesium Alloy Material.
- Equivalent Elastic Strain is higher in Magnesium Alloy Material.
- Equivalent Stress of sheet is lower in Magnesium Alloy Material.
- All the materials exceeded thier respective yield strength, which means that they are plastically deformed which is required in sheet metal bending but Aluminum Alloy 1199 failed.
Case-2: Compare Results of Aluminum alloy 1199 of Case-1 and Alluminum alloy with frictional coefficient 0.19.
Material: Aluminum Alloy for Sheet.
Boundary Conditions:
Contacts: Contacts has been applied as shown below with frictional coefficient 0.19.
Mesh:
Body Sizing: Punch and Die:- Size of element- 4mm.
Body Sizing: Sheet:- Size of element- 1mm.
Results:
Equivalent Stress:
Equivalent Elastic Strain:
Directional Deformation: Y-axis.
Equivalent Stress of Sheet:
Results Comparison:
| Directional Deformation: Y-axis | Equivalent Elastic Strain | Equivalent Stress of Sheet | ||||
| mm | * | Mpa | ||||
| Min. | Max. | Min. | Max. | Min. | Max. | |
| CASE-1(Aluminum Alloy 1199) | -13.979 | 3.7109 | 6.13E-14 | 0.22189 | 1.47E-05 | 441.46 |
| Aluminum Alloy Friction Coefficient 0.19 | -13.651 | 3.7156 | 5.15E-14 | 0.51208 | 0.00088699 | 431.47 |
- Equivalent Elastic Strain and Max. Directional deformation in Y-axis is higher in Case-2 due to an increase in frictional coefficient.
- All the materials exceeded thier respective yield strength, which means that they are plastically deformed which is required in sheet metal bending but Aluminum Alloy 1199 failed.
Case-3: Compare Results of Aluminum alloy 1199 of Case-1 and Alluminum alloy with refined mesh for the sheet, remaining settings same as Case-1.
Mesh:
Body Sizing: Punch and Die:- Size of element- 4mm.
Body Sizing: Sheet:- Size of element- 0.75mm.
Material: Aluminum Alloy for Sheet.
Contacts: Same as Case-1.
Results:
Equivalent Stress:
Equivalent Elastic Strain:
Equivalent Stress of Sheet:
Results Comparison:
| Directional Deformation: Y-axis | Equivalent Elastic Strain | Equivalent Stress of Sheet | ||||
| mm | * | Mpa | ||||
| Min. | Max. | Min. | Max. | Min. | Max. | |
| CASE-1(Aluminum Alloy 1199) | -13.979 | 3.7109 | 6.13E-14 | 0.22189 | 1.47E-05 | 441.46 |
| Aluminum Alloy Refined Mesh | -15.345 | 3.4083 | 0 | 0.23306 | 0 | 332.7 |
- Max. Directional deformation in Y-axis is highest in Case-1.
- Equivalent Elastic Strain is higher in Case-3.
- Equivalent Stress of sheet is lower in Case-1.
- All the materials exceeded thier respective yield strength, which means that they are plastically deformed which is required in sheet metal bending but Aluminum Alloy 1199 failed.