Week 3 Sheet metal Bending challenge

Sheet metal bending 

Objective: 

Stimulating sheet metal bending with three different materials of aluminum alloy 1199, copper alloy nl, magnesium alloy nl. and to find out equivalent stress, directional deformation, equivalent strain. 

Procedure: 

assigning the material properties for the given component and updating using mechanical module. 

now we have to assign frictional contacts between punch and sheet and also sheet and die. 

then we have to perform a mesh using body sizing. 

in analysis settings the number of steps we have to perform is 10 with large deflection on 

We have to give a displacement load for the punch which should be acting downwards 

Directional deformation for aluminum alloy 1199 

Equivalent stress for aluminum alloy 1199 

Equivalent stress on aluminum alloy 1199 sheet metal 

Equivalent strain for aluminum alloy 1199 

Directional deformation for copper alloy NL 

equivalent stress for copper alloy NL 

equivalent stress on copper alloy NL sheet metal 

Equivalent strain for copper alloy NL 

Directional deformation for magnesium alloy NL  

equivalent stress for magnesium alloy NL 

equivalent stress on magnesium alloy NL sheet metal 

equivalent strain for magnesium alloy NL 

Results for case 1: 

	Directional deformation	equivalent stress	equivalent elastic strain
Aluminum alloy 1199	2.345	2.3661e5	1.184
copper alloy NL	5.7438	2.303e5	1.1523
Magnesium alloy NL	1.896	2.2694e5	1.1436

For case 2 with the coefficient of friction is 0.19 and the material is aluminum alloy 1199 

Directional deformation for aluminum alloy 1199 with COF 0.19 

Equivalent stress for aluminum alloy 1199 with COF 0.19 

Equivalent stress on aluminum alloy 1199 sheet metal with COF 0.19 

Equivalent strain for aluminum alloy 1199 with COF 0.19 

Materials	Directional deformation	equivalent stress	equivalent strain
Aluminum alloy 1199 with COF (0.1)	2.345	2.3661e5	1.184
Aluminum alloy 1199 with COF (0.19)	2.2913	2.1347e5	1.0173

Case 3 refining mesh size with aluminum alloy material 

Conclusion: 

In case 1 the maximum equivalent is developed in copper alloy is minimum and with magnesium alloy as maximum. but maximum equivalent strain is more in magnesium alloy and minimum in copper alloy. 

In case 2 after increasing or coefficient of friction the maximum equivalent stress and maximum equivalent strain both increases