Week 3 Sheet metal Bending challenge

OBJECIVES:

• To find out the directional deformation in y axis and equivalent stress and strain for aluminium non linear alloy, copper alloy amd magnesium alloy with frictional coefficient of .1 and mesh size of 1 mm for sheet
• To find out the directional deformation in direcion ,equivalent stress and strain for aluminium sheet bending with .5mm mesh size and frictional coefficient of .19

PROCEDURE:

• Open the ansys workbenh R2
• select the static structural analysis
• rename as sheet metal of aluminium 1199
• choose aluminium alloy non linear from engineering data and duplicate it and change its name as aluminium alloy 1199 ,young's modulus as 62000 MPa ,yield strenth as 140 MPa and tangent modulus as 209.49 MPa
• import geomtry
• open ansys mechanical
• rename each part of body
• select material as structural steel for both die and punch and for the sheet select aluminium 1199
• delete default contacts and insert manual contact region twice
• for the first manual contact region select its contact as 3 edge of punch and its target as uppe part of aluminium sheet
• 
• for the second manual contact region select its contact as bottom isde of the sheet and target as the upper side of die
• 
• select both contact and define type as frictional and input frictional coeficient of .1 (for case 2 input frictonal coefficient as .19)
• select behavior as AUTO ASSYMMETRIC and formulation as augmented lagrange
• change normal stiffness to factor and input value of .1
• under geometric modification select interfacetreatment as Add offset, ramped effect
• define mesh size for both die and punch as 4 mm and for aluminium sheet and contactin feces of punch and die as 1 mm (for case 3 input mesh size for sheet as .8mm )
• insert method in mesh and select tetrahedrone
• in analysis settings input number of step as 10 select solver type as direct ,large defflection changed to ON condition
• select upper three faces of punch and right click on static structural and insert the displacement
• select tabular data for all three axis and input data in y axis only other two axis value keep zero for all condition
• select two wide side edge of sheet and insert the displacement ,for z axis select tabular data and input value as zero for all
• select lower part of die and other four side and insert displacement as above mentioned in all three axis as tabular data ,for x and z axis keep all value as zero and for y axis input last two value as -1.5 and -3 respecivly and other value as zero
• insert directional deformation ,equivalent stress and strain by right click on solution

• run solve

RESULT :

ALUMINIUM 1199 SHEET ( MESH SIZE 1 MM ,FRICTIONAL COEFFICEINT OF .1)

TOTAL DEFORMATION

EQUIVALENT STRAIN :

EQUIVALENT STRESS :

ALUMINIUM SHEET WITH MESH SIZE .8 MM & COEFFICIENT OF FRICTION IS .1 :-

DIRECTIONAL DEFORMATION(Y AXIS):-

EQUIVALENT STRAIN :-

EQUIVALENT STRESS :-

ALUMINIUM SHEET OF MESH SIZE 1 MM AND COEFFICIENT FRICTION IS .19:-

DIRECTIONAL DEFORMATION:-

EQUIVALENT STRAIN :-

EQUIVALENT STRESS:-

COPPER SHEET OF MESH SIZE 1MM AND FRICTIONAL COEFFICIENT OF .1:-

DIRECTIONAL DEFORMATION :-

EQUIVALENT STRAIN :-

EQUIVALENT STRESS :-

MAGNESIUM SHEET OF MESH SIZE 1MM AND FRICTIONAL COEFFICIENT OF .1:-

DIRECTIONAL DEFORMATION :-

EQUIVALENT STRAIN:-

EQUIVALENT STRESS:-

TABULATION:-

	DIRECTIONAL DEFORMATION(mm)	EQUIVALENT STRAIN(m/mm)	EQUIVALENT STRESS(MPa)
Al SHEET MESH SIZE 1MM FRICTIONAL COEFFICIENT .1	8.2023	1.2247	2.447e5
Al SHEET MESH SIZE .8MM FRICTIONAL COEFFICIENT .1	7.3801	1.2247	2.447e5
Al SHEET MESH SIZE 1MM FRICTIONAL COEFFICIENT .19	3.672	.63776	1.2683e5
Cu SHEET MESH SIZE 1MM FRICTIONAL COEFFICIENT .1	3.6915	1.0255	2.049e5
Mg SHEET MESH SIZE 1MM FRICTIONAL COEFFICIENT .1	3.7362 mm	.6502 mm/mm	1.2998e5

CONCLUSION:-

• Directional deformation is maximum for aluminium sheet of frictional coefficient of .1 and minimum for also for aluminium sheet of frictional coefficient of .19
• equivalent strain is minimum for aluminium sheet of frictional coefficient of .19 is 0.63776 mm/mm
• equivalent strain is maximum for aluminium sheet of frictional coefficient of .1 is 1.2247 and is same for both mesh size of 1mm and .8mm
• equivalent stress is minimum for aluminium sheet of frictional coefficient of .19 is 1.683e5 MPa
• equivalent stress is maximum for aluminium sheet of frictional coefficient of .1 is 2.447e5 MPa