Week 3 Sheet metal Bending challenge

Sheet metal bending

Objective:

To carry out a static structural analysis to find out Equivalent stress, Equivalent elastic strain and Total deformation on Sheet metal bending project with 3 different materials, changing coefficient factor and refining mesh size. Refer below for Details.

Case 1 – Find Equivalent stress, Equivalent elastic strain and Total deformation for Aluminum Alloy 1199, Copper Alloy NL, Magnesium alloy NL.

Case 2 – Find Equivalent stress, Equivalent elastic strain and Total deformation for Aluminum Alloy with coefficient of 0.19.

Case 3 – Find Equivalent stress, Equivalent elastic strain and Total deformation for Aluminum Alloy with fine mesh.

Contacts:

Below are the contacts for Punch, Worksheet and Die for all 3 cases.

Contact between Punch, Die and workpiece(sheet)

Here Punch, Die and Sheet are connected to each other by frictional contact and 0.1 frictional coefficient is applied.

Connection between Punch and workpiece

Connection between Die and workpiece

Support & Load details.

Below are the Supports and loads for all 3 cases.

CASE 1:

Here Aluminum Alloy 1199, Copper Alloy NL, Magnesium alloy NL are taken for the workpiece in bending operation and refer below for more details.

1. Mesh.

Refer below for Mesh details.

2. Results

2.1 Von-mises stress on workpiece with Aluminum alloy 1199

2.2 Equivalent strain on workpiece with Aluminum alloy 1199

2.3 Directional deformation on workpiece with Aluminum alloy 1199

2.4 Von-mises stress on workpiece with copper alloy NL

2.5 Equivalent strain on workpiece with Copper alloy NL

2.6 Directional deformation on workpiece with copper alloy

2.7 Von-mises stress on workpiece with Magnesium alloy NL

2.8 Equivalent strain on workpiece with Magnesium alloy NL

2.9 Directional deformation on workpiece with Magnesium alloy NL

CASE 2:

Here Aluminum alloy with friction coefficient is 0.19 has been taken for static structural analysis and refer below for more details.

Contact between Punch, Die and workpiece(sheet)

Here Punch, Die and Sheet are connected to each other by frictional contact and 0.19 frictional coefficient is applied.

1. Mesh.

Refer below for Mesh details.

2. Results

2.1 Von-mises stress on workpiece with Aluminum alloy & frictional coefficient 0.19

2.2 Equivalent strain on workpiece with Aluminum alloy & frictional coefficient 0.19

2.3 Directional deformation on workpiece with Aluminum alloy & frictional coefficient 0.19

CASE 3:

Here Aluminum alloy with fine mesh has been taken for static structural analysis and refer below for more details.

1. Mesh.

Refer below for Mesh details.

2. Results

2.1 Von-mises stress on workpiece with Aluminum alloy & fine mesh

2.2 Equivalent strain on workpiece with Aluminum alloy & fine mesh.

2.3 Directional deformation on workpiece with Aluminum alloy & fine mesh.

Conclusion

S.No	Material of workpiece	Max. Stress MPa	Equivalent elastic strain	Directional deformation MM
Case 1	Aluminum alloy 1199	3.5e5	1.77	2.31
	Copper alloy NL	2.6e5	1.3	-2.009
	Magnesium alloy NL	2.5e5	1.26	1.636
Case 2	Aluminum alloy with coefficient 0.19	3045.7	0.04	0.77
Case 3	Aluminum alloy with fine mesh	1.9e5	0.99	1.9

When comparing the above 3 cases, Case 2 has 3045.7 MPa stress, 0.77 mm Directional deformation & 0.04 Elastic strain which are less values. So, Case 2 is the best one.