Week 3 Sheet metal Bending challenge
Aim - Simulate sheet metal bending on different materials
Procedure
#CASE-1
1. Open ANSYS, create a static structural analysis system, add the materials (Al alloy 1199, Cu alloy NL, Mg alloy NL) and import the geometry.
2. Open model section. Rename the components as to your preference.
3. Assign the sheet metal material as Al alloy 1199.
4. Delete all predefined connections, add a manual conncetion and and select the faces of contact as shown.
5. Add another contact with the following faces
6. Set both contacts to be frictional contact with frictional coefficient to be 0.1, auto axisymmetric behaviour, augmented lagrange formulation. In advance settings, turn normal stiffness option to factor with a value of 0.1 and interface treatment to add offset, no ramping.
7. Add mesh. Set the sheet to have a tetrahedral mesh, body meshing with size of 1mm. The rest meshing is shown in following
8. Adjust for analysis settings. Refer the following
Results
Aluminum Alloy 1199:
1. Stress
2. Strain
3. Displacement
4. Directional Deformation
(b) Magnesium Alloy
1. Stress
2. Strain
3. Total Deformation
4. Directional Deformation
(c) Copper Alloy
1. Stress
2. Total Strain
3. Total Deformation
4. Directional Deformation
Observation
|
Max Stress (MPa) |
Min Stress (MPa) |
Max Strain |
Min Strain |
Max Directional Deformation (Y) (mm) |
Min Directional Deformation (Y) (mm) |
|
| Aluminum | 2.6145e5 | 2.4901e-10 | 1.2472 | 1.0756e-13 | 1.6773 | -13.487 |
| Magnesium | 1.6658e5 | 1.9574e-7 | 0.83356 | 9.7868e-13 | 2.2666 | -12.516 |
| Copper | 2.021e5 | 1.4158e-7 | 1.011 | 7.0984e-13 | 2.788 | -11.68 |
#CASE-2
Change the frictional coefficient to 0.19 (Al alloy)
| Frictinal Coefficient |
Stress (Max/Min) (MPa) |
Strain (Max/Min) (MPa) |
Deformation (Max/Min) (mm) |
| 0.1 | 2.6145e5/2.4901e-10 | 1.2472/1.0756e-13 | 1.6773/-13.487 |
| 0.19 | 1.2782e5/2.1411e-8 | 0.6407/1.0706e-13 | 2.2775/-12.467 |
#CASE-3
Mesh was refined. The body sizing of the sheet was reduced to 0.75. The results are as follows:
| Mesh |
Max Strain (MPa) |
Min Strain (MPa) |
Max Strain |
Min Strain |
Max Directional Deformation (mm) |
Min Directional Deformation (mm) |
| Sheet Body Sizing = 1mm | 2.6145e5 | 2.4901e-10 | 1.2472 | 1.0756e-13 | 1.6773 | -13.487 |
| Sheet Body Sizing = 0.75mm | 2.4409e5 | 1.4708e-8 | 1.2216 | 7.3579e-14 | 2.2384 | -12.379 |