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OBJECTIVE: - Perform stress analysis on sheet metal bending setup for three different material and test following cases. Case 1: Apply Aluminium Alloy 1199, Copper Alloy NL and Magnesium Alloy NL to the sheet. Find out the Equivalent stress, Equivalent elastic strain and Total Deformation in the Y direction and…
Rajiv Ranjan
updated on 06 Apr 2021
OBJECTIVE: -
Perform stress analysis on sheet metal bending setup for three different material and test following cases.
Case 1: Apply Aluminium Alloy 1199, Copper Alloy NL and Magnesium Alloy NL to the sheet. 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: -
Properties of aluminium alloy 1199-
Meshing-
The meshing for the sheet is done with tetrahedrons elements with patch conforming algorithm.Body sizing is provided to punch and die as 4mm element length and for sheet it is 1mm.Face sizing for the die and punch at the faces where they interact with each other is given as 1mm.
Connections-
Frictional contacts are provided at the interface were the punch will press the sheet, and another contact between the sheet and die.The frictional coefficient of 0.1 is inputed at both places.
Contact between the punch and the sheet-
Contact between the Sheet and the die-
Analysis settings-
Simulation is performed in 10 steps with large deflection turned "ON" to account for large deformation with solver type as direct. Convergence difficulty is due to unstable problem which is usually the result of a large displacement for small load increments. Nonlinear stabilization technique can help in achieving convergence.We can change the dissipation ratio factor to 0.1.It can be thought of as adding an artificial dampers to all the nodes.
Boundary Conditions-
Results-
CASE I: Aluminium_1199 as material for the sheet.
Equivalent stress for the aluminium sheet
Equivalent strain for the aluminium sheet-
Total deformation for the Aluminium sheet-
Von-mises stress for the sheet-
CASE II: Copper alloy NL as material for the sheet.
Equivalent stress for the Copper alloy_NL sheet
Equivalent strain for the Copper alloy_NL sheet-
Total deformation for the Copper alloy_NL sheet.
Stress for the Copper alloy_NL sheet alone-
CASE III: Magnesium alloy NL as material for the sheet.
Table: -
Materials | Maximum Equivalent Stress | Maximum Total deformation | Maximum Equivalent Strain | Maximum Equivalent stress (for sheet) |
Aluminium Alloy 1199 | 1.0059e5 MPa | 12.462 mm | 0.50 | 52.943 MPa |
Copper Alloy NL | 2.316e5 MPa | 11.669 mm | 1.16 | 109.15 MPa |
Magnesium Alloy NL | 3.155e5 MPa | 12.031 mm | 1.58 | 260.04 MPa |
From the Above table, we observe that copper alloy has the least total deformation, due to large Young’s modulus compared to other material.
CONCLUSION: -
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