Stress Analysis of Sheet Metal Bending Operation in ANSYS Workbench

Objectives:  To perform Sheet Metal Bending Operation in ANSYS Workbench

Geometrical Design:

3D Model is shown below; it is having 3 main parts named as Punch Die and Sheet.

Material Properties:

For this analysis we will consider 3 different materials for sheet. We will consider Structural Steel for Punch & Die and will consider various other materials for sheet. Have a look at material properties below;

Problem Statement:

Sheet of different materials will pressed by punch and deformation and desired shape will be obtained. Sheet will deform as per the shape of Die. Various parameters will be used to perform this analysis like different materials, different co-efficient of friction and a refined mesh. At the end of simulation we will look for Total Deformation, Equivalent Elastic Strain and Equivalent Stress.

There will be 3 cases for this analysis

Case 1: Aluminum Alloy 1199, Copper Alloy NL, Magnesium Alloy NL

Case 2: Aluminum Alloy with friction co efficient of 0.19 (Other Cases 0.1)

Case 3: Aluminum Alloy with Refined Mesh

Mesh Criterion:

Element Type: Tet and Hex Mesh

Body Sizing 1: 4 mm

Body Sizing 2: 1 mm

Face Sizing: 1 mm

Method: Patch Conforming Method (Sheet)

Mesh Model:

Mesh Refinement:

Element Quality:

Boundary Condition:

Punch Die & Sheet possess various contacts, Frictional contact between Punch & Sheet, another frictional contact between Sheet and Die.

Punch will be given displacement in Y Direction, two sides of plate is kept fixed with 0 mm displacement, die is constrained with all sides.

Displacement:

Loading & Analysis Setting:

The analysis is divided into total 10 steps.

Steps: 10 Steps

Post Process:

C1: Aluminum Alloy 1199

Directional Deformation

Equivalent Elastic Strain

Equivalent Stress

Equivalent Stress for Plate

C1: Copper Alloy

Directional Deformation

Equivalent Elastic Strain

Equivalent Stress

Equivalent Stress for Plate

C1: Magnesium Alloy

Directional Deformation

Equivalent Elastic Strain

Equivalent Stress

Equivalent Stress for Plate

C2: Aluminum Alloy with friction co-efficient of 0.19

Directional Deformation

Equivalent Elastic Strain

Equivalent Stress

Equivalent Stress for Plate

C3: Aluminum Alloy with Refined Mesh

Directional Deformation

Equivalent Stress

Equivalent Stress for Plate

Click here to see animation of this project,

Sheet Metal Bending || FEA || ANSYS Workbench

Post Process Results Summary;

Results & Conclusion:

Various Results obtained from these analyses which are summarized in above given table. Lot of various and different parameters used in this analysis such as different materials, different co efficient of friction and mesh refinements. At the end of this we gets satisfactory results.