Week 3 Sheet metal Bending challenge
Objective: To compare the Equivalent Stress, Elastic Strain, and Total Deformation (Y direction) for bending a sheet in 3 different materials. Also, to study the impact of friction coefficient and mesh refinement on the process.
Steps:
1. The required materials are assigned to each item, after geometry inspection in Space Claim.
2. The connections are defined as per the video, and parts are meshed
3. Analysis settings are set up and loads are applied, and the problem is solved by the solver:
Results:
Case 1:
The results for Aluminum Alloy 1199, Copper Alloy, and Magnesium Alloy can be tabulated as below:
| Material | Equi. Stress (MPa) | Equi. Elastic Strain (mm/mm) | Total Deformation - Y direction (mm) |
| Alu Alloy 1199 | 59.632 | .0016432 | -12.718 |
| Copper Alloy | 117.9 | .0018144 | -10.013 |
| Magnesium Alloy | 160.29 | .0092658 | -11.298 |
Case 2: Aluminum Alloy (u=0.2) Vs Aluminum Alloy 1192 (u=0.3)
The results are as below:
| Material | Equi. Stress (MPa) | Equi. Elastic Strain (mm/mm) | Total Deformation - Y direction (mm) |
| Alu Alloy (u=0.3) | 59.632 | .0016432 | -12.718 |
| Alu Alloy (u=0.19) | 62.408 | .0016543 | -12.388 |
Conclusion: The coefficient of friction has a direct impact on the results.
Case 3: Aluminum Alloy 1192 (Mesh size: 1mm) Vs Aluminum Alloy (Mesh size: 0.75 mm)
The results are as below:
| Material / Mesh size | Equi. Stress (MPa) | Equi. Elastic Strain (mm/mm) | Total Deformation - Y direction (mm) |
| Aluminum Alloy / 1mm mesh | 59.632 | .0016432 | -12.718 |
| Aluminum Alloy / 0.75 mm mesh | 134.45 | .0033615 | -12.269 |
Conclusion: Mesh refinement has a direct impact on the accuracy of the results.
NOTE: The simulation files can be downloaded from the link given below:
https://drive.google.com/file/d/1J03lOI8FAD-314YpCTMWpugMftI0t5Mb/view?usp=sharing