Performed Sheet Metal Bending with Three Different Alloys- Aluminum, Magnesium & Copper using ANSYS WorkBench

Objective: Sheet metal bending is to be performed for 3 different materials mentioned below.

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.

The theory behind bending of metals: Material expansion occurs on the outside surface of the bend, compression on the inside, and we need to know how to deal with both. The limits

of material ductility will be the controlling factor for the minimum bend radius. The strains associated with the plastic deformation when cold forming can cause the material to strain

harden. This can change the material’s mechanical properties in the area of the bend, where plastic deformation is occurring.

At this point, ductility and resistance to fracture will need to be considered. We will verify that which material has high ductility and best suitable for sheet metal bending.

What is Ductility?

• It is the property that permits a maṭerial to be drawn out longitudinally to a reduced section, under the action of tensile force.

Also, strength which enables the material to resist fracture under load.

• Strength is the most important property from the design point of view.

Model Given:

Material Assigned:

Aluminum Alloy

Copper Alloy

Magnesium Alloy

Contacts:

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 Y direction and compare the results for the three materials.

Material 1: Aluminum Alloy

Deformation

Equivalent Stress:

Strain:

Sheet Metal Stress representation:

Material 2: Copper Alloy

Deformation

Equivalent Stress:

Strain:

Stress on the sheet:

Material 3: Magnesium

Equivalent Stress:

Equivalent Strain:

Stress on sheet

Results:

Properties	Aluminum Alloy	Copper Alloy	Magnesium Alloy
Units
Stress (Mpa)	185.08	381.07	270
Strain (mm/mm)	0.002	0.003	0.006
Deformation (mm)	3.69	3.7	3.7

Aluminum is much more ductile than high-strength materials and, therefore, can be bent to a sharper radius. That’s why when bending thick or high-tensile metals, you

need to abide by a minimum inside bend radius. This will minimize the effects of strain hardening and cracking at the bend.

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Case 2: With the material as Aluminium Alloy, change the friction coefficient to 0.19 and run the analysis and compare with the Case 1.

GIF:

Deformation:

Equivalent stress:

Strain:

	Deformation	Stress	Strain
	mm	Mpa	mm/mm
Aluminum (Fric 0.1)	3.69	185.08	0.002
Aluminum (Fric 0.19)	3.7	186	0.003

There are no significant changes in the values of stresses if change the friction values. So the material is good enough to use as sheet metal bending.

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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.

Sheet Meshed with 1.0 (Previous Stats) Sheet Meshed with 0.5mm

Final Conclusion:

Through the above simulation, we judged which material is the most ductile because and that is Aluminum:

1. A good ductile material posses a high degree of plasticity and strength.

2. Ductile materials have a low degree of elasticity.

Further through the Grid Dependency Test we can judge and select better for sheet metal bending.

Through all perspective which I have performed in this project, I found out that aluminum is the best material out of the three mentioned material for sheet metal bending.