Sheet Metal Bending Analysis Using Ansys Workbench
TITLE: Static Structural Analysis on Sheet Metal Bending Using Ansys Workbench
SUMMARY: In this project, usually performing static structural analysis on a Geometric Model we have performed same analysis for three different Varying Materials. Our main focus during entire simulation had observed on how varying materials changes values of desired parameters such as Equivalent stress, Strain & Deformation.
INTRODUCTION: In order to perform mentioned analysis (Sheet Metal Bending), we had provided a model of DIE, PUNCH & Metal Sheet assembly. Firstly, to begin with we assigned required contacts & Target surfaces. The assembly should perform in such a way, that the Punch presses towards the sheet, allowing it to be bend inside mould pattern of Die. Meanwhile, the entire assembyl is then meshed. The Punch as well as Die were first meshed with an Elemental Size of 4mm then, the Metal sheet meshed with an elemental size of 1mm in tetrahedron method. Similarly, The contacting surfaces of both Punch as well as Die were also finely meshed about 1mm each.
The Punch is supposed to move downward, resulting Bending the Metal sheet into mould cavity of Die. In order to do so, we provided displacement each to all components of assembly such that, the punch punches & retracts back while the metal sheet remains in place along its axis before impact & the Die should retrack back in order to remove the metal sheet. All required displacements were given to execute job. The Analysis is performed in 10 steps, accordingly to which we also assigned various essential inputs. We list out all required parameters to be obtain, espacially along Y-Axis. Now, the simulation is run!
As mentioned, contact & Target surfaces can be seen above.
Below is the Meshed model with an Elemental size of 4mm to both Punch & Die. Meanwhile, the metal sheet as well as the contacting surfaces of Punch & Die are Meshed around 1mm each
Mesh Figure.
There are also various displacement values requires each for Punch as well as the Die to execute the motion, which are as follow.
Punch Displacement Values Die Displacement values
- CASE 1
Here, we are going to compare three different materials for the sheet metal bending & parameters such as Equivalent stress, Strain and Deformation long Y axis is compared. The materials mainly are Alluminim alloy, copper alloy & magnesium alloy.
Aluminium Alloy 1199.
Firstly, we took the alluminium alloy metal sheet and placed it in between Punch & die. After executing the job, the parameters were obtained. The properties of these materials are as follows,
EQUIVALENT STRESS:
It is found that a Max of 2.3754e5 MPa of Equivalent Stress is generatedon an Alluminum Metal sheet with 1.6173e-8 Mpa of Min. stress.
The amount of Equivalent stress generated along Y directional in an Aluminium alloy metal sheet can be seen below.
https://youtu.be/bCxGJZXwN1I Similarly,
EQUIVALENT ELASTIC STRAIN:
Amount of strain occured here are about 1.1889mm/mm
DIRECTIONAL DEFORMATION:
Directional deformation along Y axis occured around 2.3699mm.
Force Convergence graph for first 30 points had been ploted, which can be seen below.
COPPER ALLOY:
Following chart specifies the material properties of Copper alloy.
EQUIVALENT STRESS:
After completion for the aluminium alloy, a copper alloy is being introduce inside the assembly.
2.0648e5 MPa is Max. amount of stress generated on copper alloy sheet while, 1.015e-7 MPa is Min. amount.
Stress generated can be seen along the copper alloy sheet.
EQUIVALENT ELASTIC STRAIN:
AFter observation, 1.8334mm/mm is max. strain occured.
DIRECTIONAL DEFORMATION:
Here, 2.8737mm of Max & -11.656mmof min deformation had occured.
MAGNESIUM ALLOY:
Following graph shows magnesium alloy metal sheet properties.
EQUIVALENT STRESS:
Maximum amount of stress generated is 1.6612e5 MPa.
The amount of stress occured along the magnesium alloy sheet is shown below. Max. of 188.35 Mpa
EQUIVALENT ELASTIC STRAIN:
It seems that, 0.83128mm/mm of strain is generated.
DIRECTIONAL DEFORMATION:
2.819mm is Max Directional Deformation seen here,
Following Comparison Chart shows, how varying material has an affect on various parameters.
CONCLUSION:
Stress is independent of Young's Modulus. The Yield strength is different for all three materials. It is a strength at which the metal begans to deform. As per our results it's clear that Aluminium pocess maximum Yield strength. Hence it can sustain more load.
- CASE 2
Now, With the material as Aluminium Alloy, we had changed the friction coefficient to 0.19 and run the analysis as mentioned in Case 1.
CONCLUSION:
As the friction coefficient increases in Aluminium 1199 increases, there is slightly decrease in equivalent stress, Elastic Strain & Deformation.
Case 3:
Now, we Refine the mesh on the plate with an Elemental size of 0.9mm. Similar Parameters along with their values are obtained and are compared with case 1 Respectively.
CONCLUSION:
In this case, the mesh elemental size for plate is reduced from 1mm to just 0.9mm and the results are compared with case 01. It had been observed that the moment the elements ae reduced the results are getting more accurate. All parameters are slightly increases due to more fine mesh.