Week 3 Sheet metal Bending challenge

Objective : Perform analysis on three different materials and compare the results with three different cases

Analysis:

Structural analysis of sheet metal bending process will be categorized in 3 different cases with some changes of Material or Parameters are as given below:

Case_1: Aluminium Alloy 1199, Copper Alloy NL, Magnesium Alloy NL

Case_2: Aluminium Alloy with Friction Coefficient 0.19

Case_3: Aluminium Alloy with Mesh Refinement

Result :

Case 1_Aluminium Plate

Copper Alloy

Magnesium Alloy

Case2_Friction Coefficient 0.19

Case3_Mesh Refinement(0.5mm)

Tabular Data

Case	Directional Deformation(mm)	Equivalent Stress(MPa)	Equivalent Strain
Aluminium Alloy	10.377	1.5225e5	2.1459
Copper Alloy	3.6971	1.1966e5	0.59927
Magnesium Alloy	2.5068	1.1964e5	0.59974

Case	Directional Deformation(mm)	Equivalent Stress(MPa)	Equivalent Strain
Aluminium Alloy(0.1 Co-eff)	10.377	1.5225e5	2.1459
Aluminium Alloy(0.19 Co-eff)	10.389	1.5199e5	2.1422
Aluminium Alloy(0.55 mm mesh)	10.58	68545	0.96624

Conclusion:

• Sheet metal bending process is most effective in ductile material such as Aluminium, copper etc.
• This process also considers the plastic deformation. So the stress would be higher.
• Depending on the stress concentration and properties of material, bending accuracy can be different.
• From the comparison of CASE_1 & CASE_2, we can conclude that Aluminium Alloy with Coefficient of friction 0.19 give better results than Aluminium Alloy 1199. Because it has higher Young’s Modulus and it can give Elastic-Plastic behavior.
• Also from the comparison of CASE_1 and CASE_3, we can observe that Aluminium Alloy gives better results as there is a higher stress. We can see perfect stress distribution and good bending behavior due to refined mesh.