Week 3 Sheet metal Bending challenge

Objective:

Study the Sheet Metal Bending using Static Structural Analysis System for different material and effect of coefficient of friction as well as refinement of mesh. And compare results like total deformation in Y direction, Equivalent stress and Strain.

Analysis Setup:

1. Analysis System: Static Structural
2. Material Properties:

• Aluminium Alloy NL 1199

• Copper Alloy NL

• Magnesium Alloy NL

3. Mesh:
   • Body sizing of 4 mm to Punch and Die
   • Body sizing of 1 mm to Sheet
   • Face sizing of 1 mm for contact faces of Punch and Die.

4. Analysis Setting

• No of Steps: 10
• Solver Type: Direct
• Large Deformation: ON
• Energy Stabilization: Constant

5. Displacement Condition

• Punch: X and Y directions are fixed and displacement in Y direction is applied in 10 steps (-0.5, -1.5, -3, -6, -9, -12, -13.5, -12, -10, -8)

• Die: X and Y directions are fixed and displacement in Y direction is applied in last to steps (-1.5, -3)

• Sheet: X and Y directions are free and zero displacement in Z direction.

CASE 1 : Equivalent stress, Equivalent elastic strain and Total Deformation in Y direction and compare the results for the three materials.

Result Comparison:

Material	Equivalent Stress (Mpa)	Equivalent Strain	Directional Displacement (Y)	Eq. Stress in Sheet
Aluminium Alloy NL 1199	2.4899e5	1.2462	-12.618	57.274
Copper Alloy NL	2.1935e5	1.0977	-11.948	114.86
Magnesium Alloy NL	1.7261e5	0.86379	-10.934	75.033

Results Plots for Aluminium Alloy NL 1199

Result Plot	Aluminium Alloy NL 1199
Equivalent Stress (Mpa)
Equivalent Strain (Mpa)
Directional Displacement (Y)
Eq. Stress in Sheet

Results Plots for Copper Alloy NL

Result Plot	Copper Alloy NL
Equivalent Stress (Mpa)
Equivalent Strain (Mpa)
Directional Displacement (Y)
Eq. Stress in Sheet

Results Plots for Magnesium Alloy NL

Result Plot	Magnesium Alloy NL
Equivalent Stress (Mpa)
Equivalent Strain (Mpa)
Directional Displacement (Y)
Eq. Stress in Sheet

Conclusion:

1. It is observed that equivalent stress is maximum in Aluminium Alloy NL 1199 and minimum in Magnesium Alloy NL.
2. Copper Alloy NL sheet metal component has Maximum equivalent stress generated and minimum in Aluminium Alloy NL 1199.
3. Maximum Directional Displacement is observed in Aluminium Alloy NL 1199 is -12.618 mm and minimum in Magnesium Alloy is -10.934 mm.
4. Maximum equivalent strain in Aluminium alloy NL 1199 and minimum in Magnesium alloy NL.
5. From all above result we can conclude that Aluminium Alloy NL 1199 is best material for Sheet metal bending operation. As aluminium alloy NL 1199 sheet has minimum equivalent stress.

CASE 2: Effect of Coefficient of Friction

Material	Equivalent Stress (Mpa)	Equivalent Strain	Directional Displacement (Y)	Eq. Stress in Sheet
Aluminium Alloy NL 1199 (COF – 0.1)	2.4899e5	1.2462	-12.618	57.274
Aluminium Alloy NL 1199 (COF – 0.19)	1.9009e5	0.95236	-12.391	58.586

Result Plot	Aluminium Alloy NL 1199
Equivalent Stress (Mpa)
Equivalent Strain (Mpa)
Directional Displacement (Y)
Eq. Stress in Sheet

Conclusion:

1. As frictional coefficient increases, equivalent stress and strain is decreases as well as there is decrease in directional deformation in Y direction.

CASE 3: Grid Refinement Test

Material - Aluminium Alloy NL 1199	Equivalent Stress (Mpa)	Equivalent Strain	Directional Displacement (Y)	Eq. Stress in Sheet (Mpa)
Mesh of Sheet – 0.8 mm	2.4708e5	1.2366	-12.371	61.322
Mesh of Sheet – 0.7 mm	1.6423e5	0.8221	-12.376	69.793

Results Plots:

Result Plot	Aluminium Alloy NL 1199 (Mesh of Sheet – 0.8 mm)
Equivalent Stress (Mpa)
Equivalent Strain (Mpa)
Directional Displacement (Y)
Eq. Stress in Sheet (Mpa)

Result Plot	Aluminium Alloy NL 1199 (Mesh of Sheet – 0.7 mm)
Equivalent Stress (Mpa)
Equivalent Strain (Mpa)
Directional Displacement (Y)
Eq. Stress in Sheet (Mpa)

Conclusion:

1. It is observed that as mesh size is getting fine, the accuracy of results is increases.
2. As mesh size of sheet plate is getting smaller, it is overserved that equivalent stress value of sheet plate is getting stable and accurate.

 Ansys Project Download Link - https://drive.google.com/file/d/170fWwwBr39lkaBvOvkGIjeJCjhzL7w9N/view?usp=sharing