Sheet metal Bending analysis using Ansys

• Objective - Perform the sheet metal bending for different materials and settings.

  • Case 1 - Aluminium Alloy 1199(with some changes in properties), 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.
  • 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. With Aluminium alloy as material, run The analysis as in Case 1 and compare the results.

  Procedure -

• Create Static structural analysis and in engineering data select the material Aluminium Alloy 1199(with some changes in properties), Copper Alloy NL and Magnesium Alloy NL.
• Aluminium Alloy 1199(with some changes in properties).

• Copper Alloy NL.

• Magnesium Alloy NL.

• Import the geometry and check in SpaceClaim for any irregularities.

• Then open Ansys mechanical and rename the geometry and assign the material according to the cases.

• Contacts - Two contacts created.

• First contacts created between Punch and Sheet by selecting the faces. The contact type is frictional with friction coefficient of 0.1. The Behaviour is changed to Auto Asymmetric and the Formulation type used is Augmented Lagrange. The interface treatment is set to Add offset, Ramped Effects.

• Second contacts created between Sheet and Die by selecting the faces. The contact type is frictional with friction coefficient of 0.1. The Behaviour is changed to Auto Asymmetric and the Formulation type used is Augmented Lagrange. The interface treatment is set to Add offset, Ramped Effects.

• Mesh - Mesh the model with different mesh options. Using body size option punch and die is mesh in element size of 4mm.
  Similarly for sheet the body sizing option is used and mesh in element size of 1mm and patch conforming method is used for Tetrahedrons meshing.
  Using the face sizing option faces of punch and die meshed with 1mm of element size.

• Analysis Settings - The simulation runs for 10 steps. So, the number of steps is set as 10, solver type set as Direct, large deflection is set to on and stabilization set to constant method to energy and energy dissipation ratio to 0.1.

• Joint Load - Three joints are set to the geometry.

• Joint - Displacement to the punch as shown in the tabular data in negative Y-direction.

• Joint - Displacement to the sheet as shown in the tabular data and restrict the movement in Z-direction.

• Joint - Displacement to the die as shown in the tabular data in negative Y-direction.

Result -
Case 1 Aluminium Alloy 1199(with some changes in properties), Copper Alloy NL and Magnesium Alloy NL.

Aluminium Alloy 1199
Equivalent Stress Max - 2.4317e5 Mpa

Equivalent Elastic Strain Max - 1.217 mm/mm

Total Deformation Max - 1.8558 mm

Equivalent Stress on sheet Max - 137.32 Mpa

Equivalent Elastic Strain on sheet Max - 0.0025659 mm/mm

Copper Alloy NL

Equivalent Stress Max - 2.1677e5 Mpa

Equivalent Elastic Strain Max - 1.0848 mm/mm

Total Deformation Max - 2.7605 mm

Equivalent Stress on sheet Max - 114.87 Mpa

Equivalent Elastic Strain on sheet Max - 0.0017138 mm/mm

Magnesium Alloy NL

Equivalent Stress Max - 1.6773e5 Mpa

Equivalent Elastic Strain Max - 0.83929 mm/mm

Total Deformation Max - 2.7441 mm

Equivalent Stress on sheet Max - 134.81 Mpa

Equivalent Elastic Strain on sheet Max - 0.0066973 mm/mm

Conclusion -

Case 2 With the material as Aluminium Alloy, change the friction coefficient to 0.19.

Aluminium Alloy 1199 with friction of 0.1

Equivalent Stress Max - 2.4317e5 Mpa

Equivalent Elastic Strain Max - 1.217 mm/mm

Total Deformation Max - 1.8558 mm

Equivalent Stress on sheet Max - 137.32 Mpa

Equivalent Elastic Strain on sheet Max - 0.0025659 mm/mm

Aluminium Alloy 1199 with friction of 0.19

Equivalent Stress Max - 2.1582e5 Mpa

Equivalent Elastic Strain Max - 1.0831 mm/mm

Total Deformation Max - 2.4038 mm

Equivalent Stress on sheet Max - 58.661 Mpa

Equivalent Elastic Strain on sheet Max - 0.0015401 mm/mm

Conclusion -

Case 3 Refine the mesh on the plate. With Aluminium alloy as material.

Aluminium Alloy 1199 with mesh of 1mm on sheet(plate)

Equivalent Stress Max - 2.4317e5 Mpa

Equivalent Elastic Strain Max - 1.217 mm/mm

Total Deformation Max - 1.8558 mm

Equivalent Stress on sheet Max - 137.32 Mpa

Equivalent Elastic Strain on sheet Max - 0.0025659 mm/mm

Aluminium Alloy 1199 with mesh of 0.6mm on sheet(plate)

Equivalent Stress Max - 2.2197e5 Mpa

Equivalent Elastic Strain Max - 1.111 mm/mm

Total Deformation Max - 2.2646 mm

Equivalent Stress on sheet Max - 77.565 Mpa

Equivalent Elastic Strain on sheet Max - 0.0016865 mm/mm

Conclusion -

• Case 1 - For all the material Aluminium Alloy 1199, Copper Alloy NL and Magnesium Alloy NL the Equivalent stress, Equivalent elastic strain and Total Deformation in Y direction results obtained.
• Case 2 -Using Aluminium Alloy 1199 with friction of 0.19 developed Stress and Strain is low as compared to Aluminium Alloy 1199 with friction of 0.1.
• Case 3 - Aluminium Alloy 1199 with mesh of 1mm on sheet(plate) developed Stress and Strain is low as compared to Aluminium Alloy 1199 with mesh of 0.6mm on sheet(plate).

• Google drive link - https://drive.google.com/file/d/1ncVsSBdRuJ1GibLTPLlx9jIWRWG3L0DX/view?usp=sharing/