Week 3 Sheet metal Bending challenge

Objective: To compare Total Deformation, Equivalent stress and Total Deformation in Y direction of Aluminium alloy 1199, Copper alloy and Magnesium alloy sheet in Die and Punch. To compare all the outcomes above in Aluminium alloy with coefficient of friction 0.1 and 0.19. To compare all the outcomes above in Aluminium alloy sheet after refining mesh.

Setup:

Engineering data:

Structural steel material

1) Created Aluminium alloy 1199 with properties

2) Copper alloy

3) Magnesium alloy

Geometry:

• exported file of Aluminium sheet bending.x_t

Model:

Geometry: renamed parts as Punch, Die, and Sheet

Case 1: sheet material = Aluminium alloy 1199

Case 2: sheet material = Copper alloy

Case 3 : sheet material= Aluminium alloy

Coordinate system: no change

Connections:

Contacts:

• frictional- Punch to Sheet
• Frictional- Sheet to Die

Mesh:

• 4mm mesh to Punch and Die
• 1mm mesh to sheet
• Face sizing: 1mm mesh to 10 faces in contact of Punch and Die where analysis is important.
• Patch confirming method: tetrahedrons for sheet.

Static structural:

• Analysis setting

1. Number of steps =10
2. Current step number =1
3. Silver type = direct
4. Auto time stepping= program controlled
5. Large deflection: on
6. Stabilization : constant
7. Energy dissipation : 0.1

• Displacement

Three faces of Punch, tabular data in X, Y and Z components. Values put in Y direction

• Displacement 2

Side faces of Sheet in Z component only, X and Y are free. All values 0 in z component

• Displacement 3

Five faces of Die, tabular data in X, Y and Z components. Values put in Y direction.

Solution 1:

CASE 1: sheet material= Aluminium alloy 1199

1) Equivalent stress

2) Equivalent strain

3) Deformation in Y axis

CASE 2: sheet material= Copper alloy

1) Equivalent stress

2) Equivalent strain

3) Deformation in Y axis

CASE 3: sheet material= Magnesium alloy

1) Equivalent stress

2) Equivalent strain

3) Deformation in Y axis

Solution 2:

Comparision of Bending of Aluminium alloy 1199 with coefficient of friction 0.1 and 0.19.

Solution 3:

Comparision of Aluminium alloyy 1199 sheet with mesh 1mm and refined mesh (0.75mm).