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 result like total deformation in y direction, equivalent stress and strain.
Analysis setup
1. Analysis system : static structural
2. Material properties:
Aluminium Alloy NL1199
copper Alloy NL
Magnesium Alloy NL
3. Mesh:
Body sizing of 4mm to punch and die
Body sizing of 1mm to sheet
facing sizing of 1mm 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 direction are fixed and displacement in Y direction in 10 steps (-0.5,-1.5,-3,-6,-9,-12,-13.5,-12,-10,-8)
Die: X and Y direction are fixed and displacement in y direction is applied in last to steps (-1.5,-3)
sheet: X and Y direction are free and zero displacement in z direction.
case 1: equivalent stress, equivalent elastic strain and total deformation in Y direction and compare the result for the three materials.
result comparision:
Material equivalent stress (Mpa) equivalent strain directional displacement eq. stress in sheet
Aluminium Alloy 2.4899e5 1.2462 -12.618 57.274
NL 1199
copper Alloy NL 2.1935e5 1.0977 -11.948 114.86
Magnesium Alloy
NL 1.7261e5 0.86379 -10.934 75.033
Result plot for Aluminium Alloy NL 1199
Result plot Aluminium Alloy NL 1199
Equivalent stress(Mpa)
Equivalent strain(Mpa)
Directional Displacement(y)
eq.stress in sheet
Result plot for copper Alloy NL
Result plot copper Alloy NL
Equivalent stress(Mpa)
Equivalent strain(Mpa)
Directional Displacement(y)
eq.stress in sheet
Result plot 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 -12.618mm and minimum in magnesium Alloy NL.
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 eq. stress in sheet
Aluminium 2.4899e5 1.2462 -12.618 57.274
Alloy NL 1199
(COF-0.1)
Aluminium 1.9009e5 0.95236 -12.391 58.586
Alloy NL 1199
(COF-0.19)
Result plot Aluminium Alloy NL 1199
equivalent stress (Mpa)
equivalent strain
directional displacement
eq. stress in sheet
Conclusion:
1. As frictional coefficient increases, equivalent stress and strain in decrease as well as there is decrease in directional deformation in y direction.
case 3: grid refinement test
Material equivalent stress (Mpa) equivalent strain directional displacement eq. stress in sheet
Mesh of sheet
0.8mm 2.4708e5 1.2366 -12.371 61.322
Mesh of sheet
0.7mm 1.6423e5 0.8221 -12.376 69.793
Result plots
Result plots Aluminium Alloy NL 1199(Mesh of sheet (-0.8m)
Equivalent stress(Mpa)
Equivalent strain(Mpa)
Directional Displacement(y)
eq.stress in sheet
Result plot Aluminium Alloy NL 1199( Mesh of sheet-0.7mm)
Equivalent stress(Mpa)
Equivalent strain(Mpa)
Directional Displacement(y)
eq.stress in sheet
Conclusion:
1. it is observed that as mesh size is getting fine, the accuracy of result is increase.
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.