Static Structural Analysis of Sheet bending with Different materials using ANSYS WORKBENCH
Objective: Perform Static Structural Analysis of Sheet Metal Bending with different materials using ANYSYS WORKEBENCH
Setup:
Geometry
Contacts with Settings
Mesh
The faces that will be in contact during simulation has been kept 2 mm mesh size and rest is kept with global mesh size of 4 mm. Tetrahedrons is use for method.
Analysis settings:
Displacement given for Punch in negative Y direction
Displacement given for Sheet by fixing faces
Fixed Support is given on faces of Die
Materials used during Simulation:
Aluminium Alloy NL 1199(Density 62000 MPa, Yield strength 140 MPa, Tangent Modulus 209.46 MPa) , Aluminium NL Alloy
Copper NL Alloy , Magnesium NL Alloy
Case 1:
Comparing results of Aluminium alloy 1199 , Copper NL alloy , Magnesium NL alloy:
Aluminium Alloy 1199
Directional Deformation Y Axis:
Min.= -13.78 mm , Max.= 3.68 mm
Equivalent elastic strain:
Min.= 1.30e-17 , Max.= 3.06e-3
Equivalent Von mises Stress:
Min.= 2.61e-12 MPa , Max.= 189.2 MPa
Copper NL Alloy
Directional Deformation Y Axis:
Min.= -13.62 mm , Max.= 3.69 mm
Equivalent elastic strain:
Min.= 7.71e-17 , Max.= 3.55e-3
Equivalent Von mises Stress:
Min.= 1.54e-11 MPa , Max.= 388.88 MPa
Magnesium NL Alloy
Directional Deformation Y Axis:
Min.= -13.60 mm , Max.= 3.74 mm
Equivalent elastic strain:
Min.= 5.45e-15 , Max.= 6.505e-3
Equivalent Von mises Stress:
Min.= 1.06e-9 MPa , Max.= 271.33 MPa
|
Material |
Deformation along Y axis mm |
Equivalent elastic strain |
Equivalent von mises stress MPa |
|||
|
Min |
Max |
Min |
Max |
Min |
Max |
|
|
AL NL 1199 |
-13.78 |
3.68 |
1.30e-17 |
3.06e-3 |
2.61e-12 |
189.2 |
|
Copper NL |
-13.62 |
3.69 |
7.71e-17 |
3.55e-3 |
1.54e-11 |
388.88 |
|
Magnesium NL |
-13.60 |
3.74 |
5.54e-15 |
6.05e-3 |
1.06e-9 |
271.33 |
Comparing results:
- For Deformation along Y axis, Magnesium NL alloy is deformed with Maximum value of 3.74 mm and Minimum deformed is AL NL 1199 with value of -13.78 mm
- For Elastic strain, Maximum strain value is of Magnesium alloy with value of 6.05e-3 and Minimum value is of Copper NL alloy with value of 7.71e-17
- For Von mises stress, Maximum stress value is 388.88 MPa which is of Copper NL and Minimum value is 2.61e-12 MPa of AL NL 1199
Case 2:
Comparing results of Aluminium NL alloy with friction 0.1 and With friction 0.19
Aluminium NL alloy friction 0.19
Directional Deformation Y Axis:
Min.= -13.65 mm , Max.= 3.71 mm
Equivalent elastic strain:
Min.= 2.97e-17 , Max.= 5.25e-3
Equivalent Von mises Stress:
Min.= 5.93e-12 MPa , Max.= 371.14 MPa
|
Material |
Deformation along Y axis mm |
Equivalent elastic strain |
Equivalent von mises stress MPa |
|||
|
Min |
Max |
Min |
Max |
Min |
Max |
|
|
AL 1199 |
-13.78 |
3.68 |
1.30e-17 |
3.06e-3 |
2.61e-12 |
189.2 |
|
AL NL fric 0.19 |
-13.65 |
3.71 |
2.97e-17 |
5.25e-3 |
5.93e-12 |
371.14 |
Comparing results:
- For Deformation along Y axis, Aluminium NL alloy with fric 0.19 is deformed with Maximum value of 3.71 mm
- For Elastic strain, Maximum strain value is of Aluminium NL alloy with fric 0.19 with value of 5.25e-3
- For Von mises stress, Maximum stress value is 371.14 MPa which is of Aluminium NL alloy with fric 0.19
Case 3:
Comparing results of Aluminium NL alloy with mesh size 1mm and With Refined mesh 0.9 mm
Aluminium NL alloy with mesh size 0.9 mm
Directional Deformation Y Axis:
Min.= -13.62 mm , Max.= 3.69 mm
Equivalent elastic strain:
Min.= 6.78e-16 , Max.= 5.30e-3
Equivalent Von mises Stress:
Min.= 1.35e-10 MPa , Max.= 375.42 MPa
|
Material |
Deformation along Y axis mm |
Equivalent elastic strain |
Equivalent von mises stress MPa |
|||
|
Min |
Max |
Min |
Max |
Min |
Max |
|
|
AL 1199 Mesh 1 mm |
-13.78 |
3.68 |
1.30e-17 |
3.06e-3 |
2.61e-12 |
189.2 |
|
AL NL Mesh 0.9 mm |
-13.62 |
3.69 |
6.78e-16 |
5.30e-3 |
1.35e-10 |
375.42 |
Comparing results:
- For Deformation along Y axis, Aluminium NL alloy with 0.9 mm mesh is deformed with Maximum value of 3.69 mm
- For Elastic strain, Maximum strain value is of Aluminium NL alloy with 0.9 mm mesh with value of 5.25e-3
- For Von mises stress, Maximum stress value is 375.42 MPa which is of Aluminium NL alloy with 0.9 mm mesh
Conclusion:
- For case 1, Deformation along Y axis, Magnesium NL alloy is deformed Maximum .For Elastic strain, Maximum strain value is of Magnesium alloy.For Von mises stress, Maximum stress value is of Copper NL.
- For case 2, Aluminium NL Alloy with Fric 0.19 is best in terms of deformation along Y , Strain and Stress.
- For case 3, Aluminium NL alloy with 0.9 mm mesh is best in terms of deformation along Y , Strain and Stress.