Week 3 Sheet metal Bending challenge
Sheet metal Bending challenge
AIM
To carry out a static structural analysis on bevel gear with given material.
PROCEDURE
To find and compare the results of Equivalent stress, Total deformation, Equivalent elastic strain for all the cases.
Case 1: Aluminium Alloy 1199,
Case 2: Copper Alloy NL,
Case 3: Magnesium Alloy NL.
Case 2: Aluminium Alloy friction coefficient to 0.19.
Case 3: Refine the mesh on the plate.
Sheet metal bending is to be performed for 3 different materials mentioned below. Variation of certain settings is also to be performed and your conclusions are to be added to the report
Note: Please read the instructions carefully
Run the analysis for the material :
Case 1:Aluminium Alloy 1199( mentioned in the course video), Copper Alloy NL, and Magnesium Alloy NL. Find out the Equivalent stress, Equivalent elastic strain, and Total Deformation in the Y direction and compare the results for the three materials.
Case 2:With the material as Aluminium Alloy, change the friction coefficient to 0.19 and run the analysis as mentioned in Case 1. Compare the results with that in case 1.
Case 3: Refine the mesh on the plate such that it doesn't cross the academic limit. With Aluminium alloy as material, run the analysis as in Case 1 and compare the results.
Submit the challenge as you would do in a proper project report with all relevant details such as settings, mesh size, images, and tables included to provide your findings. Also, give an explanation as to which property/ properties of the materials affect the outcome
Case 1: Aluminium Alloy 1199, Copper Alloy NL, and Magnesium Alloy NL.
Aluminium Alloy 1199( mentioned in the course video), Copper Alloy NL, and Magnesium Alloy NL. Find out the Equivalent stress, Equivalent elastic strain, and Total Deformation in the Y direction and compare the results for the three materials.
Import the geometry.
select the material.
strainless steel.
Aluminium Alloy 1199
And open the model panel.
In connection panel connect the press and sheet.
And connect the sheet and die.
contact size = frictional.
behaviour = Asymmentry.
formulation = augmented tagrange.
interface treatment = add offset and ramped effect.
frictional co-efficient = 0.1
In connection panel connect the press and sheet.
And connect the sheet and die.
mesh the component with element sizing of 4mm for the press and die.
mesh the component with element sizing of 1mm.
mesh the component with element face sizing of 1mm.
Analysis setting
step = 10
stabilization = consstant.
Energy disstabilization = 0.1
solver control = direct
large deformation = on
dispacement
dispacement 2
dispacement 3
directional deformation
Equivalent stress
Equivalent elastic strain
Case 2: Copper Alloy NL
Import the geometry.
select the material.
strainless steel.
copper NL
And open the model panel.
In connection panel connect the press and sheet.
And connect the sheet and die.
contact size = frictional.
behaviour = Asymmentry.
formulation = augmented tagrange.
interface treatment = add offset and ramped effect.
frictional co-efficient = 0.1
In connection panel connect the press and sheet.
And connect the sheet and die.
mesh the component with element sizing of 4mm for the press and die.
mesh the component with element sizing of 1mm.
mesh the component with element face sizing of 1mm.
Analysis setting
step = 10
stabilization = consstant.
Energy disstabilization = 0.1
solver control = direct
large deformation = on
dispacement
dispacement 2
dispacement 3
Directional deformation
strain
stress
Case 3: Magnesium Alloy NL.
Import the geometry.
select the material.
strainless steel.
magnesium alloy
And open the model panel.
In connection panel connect the press and sheet.
And connect the sheet and die.
contact size = frictional.
behaviour = Asymmentry.
formulation = augmented tagrange.
interface treatment = add offset and ramped effect.
frictional co-efficient = 0.1
In connection panel connect the press and sheet.
And connect the sheet and die.
mesh the component with element sizing of 4mm for the press and die.
mesh the component with element sizing of 1mm.
mesh the component with element face sizing of 1mm.
Analysis setting
step = 10
stabilization = consstant.
Energy disstabilization = 0.1
solver control = direct
large deformation = on
dispacement
dispacement 2
dispacement 3
Directional deformation
strain
stress
Import the geometry.
select the material.
strainless steel.
Aluminium Alloy
And open the model panel.
In connection panel connect the press and sheet.
And connect the sheet and die.
contact size = frictional.
behaviour = Asymmentry.
formulation = augmented tagrange.
interface treatment = add offset and ramped effect.
frictional co-efficient = 0.19
In connection panel connect the press and sheet.
And connect the sheet and die.
mesh the component with element sizing of 4mm for the press and die.
mesh the component with element sizing of 1mm.
mesh the component with element face sizing of 1mm.
Analysis setting
step = 10
stabilization = consstant.
Energy disstabilization = 0.1
solver control = direct
large deformation = on
dispacement
dispacement 2
dispacement 3
Directional deformation
strain
stress
Import the geometry.
select the material.
strainless steel.
Aluminium Alloy 1199
And open the model panel.
In connection panel connect the press and sheet.
And connect the sheet and die.
contact size = frictional.
behaviour = Asymmentry.
formulation = augmented tagrange.
interface treatment = add offset and ramped effect.
frictional co-efficient = 0.1
In connection panel connect the press and sheet.
And connect the sheet and die.
mesh the component with element sizing of 4mm for the press and die.
mesh the component with element sizing of 0.7mm.
mesh the component with element face sizing of 1mm.
Analysis setting
step = 10
stabilization = consstant.
Energy disstabilization = 0.1
solver control = direct
large deformation = on
dispacement
dispacement 2
dispacement 3
Directional deformation
strain
stress
RESULT
Material Directional deformation Strain Stress
Aluminium Alloy 1199 2.3204MAX 0.39717MAX 79360MAX
Copper Alloy NL 6.1902MAX 0.59047MAX 1.1794E5MAX
Magnesium Alloy NL 5.1508MAX 0.39251MAX 78387MAX
Aluminium Alloy 0.77427MAX 0.04362MAX 3095.8MAX
Aluminium alloy(small mesh) 0.76196MAX 0.043658MAX 3098.5MAX