Week 3 Sheet metal Bending challenge
Case Study for Stress, Strain, Total Deformation on Sheet Metal Bending.
Objective:
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.
Procedure:
Case1:
For Case 1, Static Structural Analysis is carried out on Sheet. The material is Aluminum Alloy 1199 and the analysis is carried out on Ansys Workbench. The geometry of the model is imported on the Ansys Workbench for analysis. The geometry of the model is first checked in the space claim.
2D Geometry is extruded in the Space Claim to get the model to be imported to the ANSYS. The Extruded model is as shown in the image below:
The properties of the material is stated below:
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Young's Modulus |
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Poisson's Ratio |
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Bulk Modulus |
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Shear Modulus |
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Equivalent Stress, Equivalent Elastic Strain and Total Deformation in the Y-Direction are carried out and compared for the three different materials, i.e Aluminum Alloy 1199, Copper Alloy NL and Magnesium Alloy NL.
The simulation is then run with the setting and the results are then obtained.
Results:
Total deformation in the Y-Direction of the 3 cases are compared.
Material Type Minimum [mm] Maximum [mm] Average [mm]
Aluminum Alloy 1.928 12.492 6.166
Copper Alloy NL 2.129 9.909 5.494
Magnesium Alloy NL 2.033 12.608 6.149
Equivalent Stress of the 3 cases are compared.
Material Type Minimum [Mpa] Maximum [Mpa] Average [Mpa]
Aluminum Alloy 1.72799E-08 245781.67127 3679.5121
Copper Alloy NL 1.33196E-07 206018.13594 3879.3397
Magnesium Alloy NL 1.691989E-07 193715.89879 4662.2283
Equivalent Elastic Strain of the 3 cases are compared.
Material Type Minimum [Mpa] Maximum [Mpa] Average [Mpa]
Aluminum Alloy 8.6410E-14 1.2301 0.0197
Copper Alloy NL 6.6599E-13 1.0310 0.0206
Manganese Alloy NL 8.4600E-13 0.9693 0.0247
Case 2:
For Case 2, Static Structural Analysis is carried out on Sheet. With co-efficient of friction as 0.19 and the analysis is carried out on Ansys Workbench.
Total deformation in the Y-Direction of the 2 cases are compared.
Time (s) Minimum [mm] Maximum [mm] Average [mm]
- 12.492 2.3236 5.30830.1 (Case 1)
- 12.386 2.4845 5.2655 (Case 2)
Equivalent Stress of the 2 cases are compared.
Time (s) Minimum [Mpa] Maximum [Mpa] Average [Mpa]
- 1.728e-008 2.4578e+005 3679.5 (Case 1)
- 1.516e-008 1.8357e+005 4120.7 (Case 2)
Equivalent Elastic Strain of the 2 cases are compared.
Material Type Minimum [Mpa] Maximum [Mpa] Average [Mpa]
- 8.6411e-014 1.2301 1.9757e-002
- 7.5801e-014 0.91993 2.1798e-002
Case 3:
For Case 3, Static Structural Analysis is carried out on Sheet. With the Mesh Size 0f 1 mm of the sheet and the analysis is carried out on Ansys Workbench.
Time (s) Minimum [mm] Maximum [mm] Average [mm]
- 12.492 2.3236 5.30830.1 (Case 1)
- 12.38 2.4351 5.8121 (Case 2)
Equivalent Stress of the 2 cases are compared.
Time (s) Minimum [Mpa] Maximum [Mpa] Average [Mpa]
- 3.1519e-003 63.876 9.3103 (Case 1)
- 7.7077e-004 81.774 12.668 (Case 2)
Equivalent Elastic Strain of the 2 cases are compared.
Material Type Minimum [Mpa] Maximum [Mpa] Average [Mpa]
- 8.6411e-014 1.2301 1.9757e-002 (Case 1)
- 6.1713e-014 0.70158 4.388e-003 (Case 2)
The total deformation on the gear is as plotted and is shown on the plate below.
The Equivalent stress is plotted on the plate and is as shown below.
The Equivalent strain is plotted on the plate and is as shown below.
Conclusion:
The Analysis was run succesfully, within the limits of the academic license, the simulation for the 3 cases were examined.