Week 3 Sheet metal Bending challenge

Objective of challenge:

1. To perform the simulation of Sheet metal Bending and execute it by appyling materails Aluminium Alloy 1199, Copper Alloy NL and Magnesium Alloy NL. Compare Equivalent stress, Equivalent elastic strain and Total Deformation in Y direction for 3 materials.
2. To perform the simulation of Sheet metal Bending and execute it by appyling materails Aluminium Alloy 1199 coefficient friction 0.1 and Aluminium Alloy 1199 coefficient friction 0.19. Compare the results.
3. To perform the simulation of Sheet metal Bending and execute it by appyling materails Aluminium Alloy 1199 refine mesh and compare with case 1.

Description	Case studies					Comments
Material	Equivalent stress(Von-Mises stress)	Sheet Equivalent stress(Von-Mises stress)	Equivalent elastic strain	Sheet Equivalent elastic strain	Total Deformation in Y direction
Mesh element size	4mm	4mm	4mm	4mm	4mm
Mesh face sizing	1mm	1mm	1mm	1mm	1mm
Aluminium Alloy 1199	Max 2.5141e5 Mpa	Max 57.999 Mpa	Max 1.2582 mm	Max 0.001609 mm	Max 2.2881 mm	1. On sheet maximum stress and strain found on middle of bending curvature area. 2. On sheet maximum deformation found on edges of both sides.
Copper Alloy NL	Max 2.3005e5 Mpa	Max 119.52 Mpa	Max 1.1514 mm	Max 0.0017797 mm	Max 2.8163 mm	1. On sheet maximum stress and strain found on middle of bending curvature area. 2. On sheet maximum deformation found on edges of both sides.
Magnesium Alloy NL	Max 1.7705e5 Mpa	Max 195.35 Mpa	Max 0.88952 mm	Max 0.0064783 mm	Max 1.294 mm	1. On sheet maximum stress and strain found on right side front edge. 2. On sheet maximum deformation found on edges of both sides.
Conclusion	Maximum stress on die found for Aluminium alloy 1199	Maximum stress on sheet found on Magnesium alloy NL	Maximum strain on die found for Aluminium alloy 1199	Maximum strain on sheet found on Magnesium alloy NL	Maximum deformation on sheet found on Copper alloy NL

Description	Case studies					Comments
Material	Equivalent stress(Von-Mises stress)	Sheet Equivalent stress(Von-Mises stress)	Equivalent elastic strain	Sheet Equivalent elastic strain	Total Deformation in Y direction
Mesh element size	4mm	4mm	4mm	4mm	4mm
Mesh face sizing	1mm	1mm	1mm	1mm	1mm
Aluminium Alloy 1199 Friction coefficient 0.1	Max 2.5141e5 Mpa	Max 57.999 Mpa	Max 1.2582 mm	Max 0.001609 mm	Max 2.2881 mm	1. On sheet maximum stress and strain found on middle of bending curvature area. 2. On sheet maximum deformation found on edges of both sides.
Aluminium Alloy 1199 Friction coefficient 0.19	Max 1.6814e5 Mpa	Max 58.677 Mpa	Max 0.84246 mm	Max 0.0016062 mm	Max 2.5916 mm	1. On sheet maximum stress and strain found on middle of bending curvature area. 2. On sheet maximum deformation found on edges of both sides.
Conclusion	Maximum stress on die found for Aluminium alloy 1199 COF 0.1	Maximum stress on sheet found on Aluminium alloy 1199 COF 0.19	Maximum strain on die found for Aluminium alloy 1199 COF 0.1	Maximum strain on sheet found on Aluminium alloy 1199 COF 0.1	Maximum deformation on sheet found on Aluminium alloy 1199 COF 0.19

Description	Case studies
Material	Equivalent stress(Von-Mises stress)	Sheet Equivalent stress(Von-Mises stress)	Equivalent elastic strain	Sheet Equivalent elastic strain	Total Deformation in Y direction
Aluminium Alloy 1199 Mesh element size 4mm Mesh sheet sizing 1mm	Max 2.5141e5 Mpa	Max 57.999 Mpa	Max 1.2582 mm	Max 0.001609 mm	Max 2.2881 mm
Aluminium Alloy 1199 Mesh element size 4mm Mesh sheet sizing 0.75mm	Max 2.5042e5 Mpa	Max 60.52 Mpa	Max 1.2532 mm	Max 0.0016199 mm	Max 2.1265 mm
Aluminium Alloy 1199 Mesh element size 4mm Mesh sheet sizing 0.5mm	Max 0.60113e5 Mpa	Max 83.138 Mpa	Max 0.30083 mm	Max 0.0016649 mm	Max 2.6616 mm
Conclusion	1. For "Mesh sheet sizing of 1mm and 0.75mm simulation results found with minor diferrences. 2. For "Mesh sheet sizing of 0.5mm simulation results found major differences when compare to 1mm and 0.75mm. Refine meshing of simulation results found increased values on sheet stress and strain and decreased values on die stress and strain.