Week 3 Sheet metal Bending challenge

 

OBJECTIVE:

The sheet metal bending simulation is to be performed on the sheet made of different materials namely

1. Aluminum alloy
2. Copper alloy
3. Manganese alloy

The analysis to be performed for three parameters viz. Equivalent vonmisses stress, Equivalent von misses strain, Total deformation. Also the analysis of the above mentioned parameters has to be performed for two different values of contact frictional coefficient viz. 0.1 & 0.19

CASE SETUP:

GEOMETRY- The geometry consist of punch, die & a sheet. This components was named for the further references   

ENGINEERING DATA- Three materials were selected and added in the engineering data material list viz. aluminum NL , Manganese NL , Copper NL. Also the physical data for aluminum is modified.

CONNECTION- Here the contacts are defined, there are two different contacts that have been defined

1. Contact between punch and sheet
2. Contact between sheet and die .

Both of the contact type is frictional with a coefficient of friction equal to 0.1 & 0.19

MESH- The size of mesh is refined for the sheet and the contact faces of sheet with die and punch because that is the critical region of analysis. The size of refined mesh is 1mm and the type of mesh is tetrahedron

ANALYSIS SETTINGS-  The entire drawing operation is simulated in 10 different steps so that the displacements can be vividly described. Displacement for punch, die is defined keeping the sheet free to move in X & Y direction but fixing its Z direction for simulating an planar motion.

RESULTS OF CASE-1- ALUMINUM SHEET

VON MISSES STRAIN= 0.00155

 

von mises stress= 58 MPa

Y-axis deformation= 2.29 mm 

COPPER ALLOY SHEET:

strain= 0.00173

stress= 140 MPa

Deformation = 5.342 mm

 Magniseum alloy sheet :

  Stress = 95 MPa

 

Strain = 0.0028

Deformation = 1.512 mm

RESULT OF CASE-2:

 

STRESS= 59 MPa

DEFORMATION = 2.29 mm

STRAIN = 0.00155

RESULT FOR CASE -3 :

For the case of mesh refinement following results are obtained

Stress= 63.87 MPa

Strain = 0.00154 

Deformation = 2.3 mm

CONCLUSION :

The stress, strain and deformation values for 3 materials of the given sheet are collected as it can be seen that highest stresses  is developed in the copper alloy sheet and also the yield strength is greater in copper.

However in the aluminum sheet the ratio of yield strength and the stresses  developed is highest

Hence, aluminum sheet will be preferred in the following application.

MATERIAL	STRESS	STRAIN	DEFORMATION-Y AXIS	YEILD STRENGTH
Al alloy	64 MPa	0.0154	2.3 mm	140 MPa
Cu alloy	140 MPa	0.00173	5.342 mm	280 MPa
Mg alloy	95 MPa	0.0028	1.512 mm	193 MPa