Week 3 Sheet metal Bending challenge

Sheet Metal Bending Challenge:-

Objective:-

To perform sheet metal Bending operation in Ansys Workbench

1.Geometric design:-

The 3D model is shown below, It is having three parts as Punch, Die, and Sheet

                           Fig 1. Geometry

There will be three cases for analysis:-

Case 1:- Aluminium alloy NL, Magnesium alloy N L, Copper alloy N L.

Case 2:- Aluminum alloy with friction coefficient 0.19 ( other case is 0.1 )

Case 3:- Aluminium alloy with Refined mesh.

2.Mesh Criterion:-

Element type: Tet and Hexa mesh

Body sizing 1: 4mm

Body sizing 2: 2mm

Face sizing: 1mm

Method: Patch conforming method ( Sheet)

3. Boundary Condition:-

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

Punch will be given displacement in the Y direction, and two sides of the Plate are kept fixed with 0 mm displacement, die is constrained with all sides.

4.Contacts:-

                                               Fig 2. Contact 1

                                             Fig 3. Contact 2

5.Displacement settings:-

                                          Fig 4. Displacement settings

6.Analysis Settings:-

                     Fig 5. Analysis settings

7. Post-process:-

Case 1

 7.1 Aluminum alloy 1199

                                        Fig 6. Equivalent stress

                                     Fig 7. Equivalent elastic strain

                                   Fig 8. Directional Deformation

7.2:- Copper alloy 

                                       Fig 9. Equivalent stress

                                    Fig 10. Equivalent elastic strain

                                         Fig 11.Directional Deformation

7.3 Magnesium alloy 

                                            Fig 12. Equivalent stress

                                           Fig 13. Equivalent elastic strain

                                            Fig 14. Directional Deformation

Case 2:- Aluminum alloy with a friction coefficient of 0.19

                                                     Fig 15. Equivalent stress

                                                  Fig 16. Equivalent elastic strain

                                                     Fig 17. Directional Deformation

Case 3:- Aluminum alloy ( Refined mesh )

                                                             Fig 18. Equivalent stress

                                                       Fig 19. Equivalent elastic strain 

                                                               Fig 20.Directional Deformation

Conclusion:-

Various Results were obtained from the analysis which is summarized in the above-given table, Lot of various and different parameters were used in this analysis such as different materials, different coefficients of friction, and mesh refinements, At the end of this, we get satisfactory results.