Week 3 Sheet metal Bending challenge

SHEET METAL BENDING CHALLENGE

Objective:- To Simulate sheet metal bending challenge with three different materials (Aluminium Alloy 1199, Copper Alloy NL & Magnesium Alloy NL) and find out Equivalent Stress, Equivalent Elastic Strain & Total Deformation.

First to import the given model and select the material one by one. Image of the 3D model given below:

• After that select material from the Library for Sheet and for Punch and Die I select Structural Steel. Properties of materials given below:

• Now come to connections in this challenge only frictional contacts are acting between Punch and Sheet and between Sheet and Die. Contacts details given below:

• Now come to details of mesh:

• Now to Details of Analysis Setting:

• Now come to different loads acting on this simulation. Image of loads given below:

• Now come to results:

Now come to Case 2 with the coefficient of Friction is 0.19 and material is Aluminium Alloy 1199.

• Detail of Frictional Contacts given below:

• Comparision OF RESULTS :

NOW COME TO CASE THREE WITH REFINE MESH SIZE WITH ALUMINIUM ALLOY MATERIAL:

• Detail of mesh given below:

• Comparision of Results with case one:

Conclusion

In Case one maximum Equivalent stress developed in Copper Alloy NL is minimum and maximum in Magnesium Alloy NL. But Maximum Equivalent Strain Is More in Magnesium Alloy NL and Minimum in Copper Alloy NL. Because Copper Alloy NL is softer then Magnesium Alloy NL.

In case two if we increase the Coefficient of Friction the Maximum Equivalent Stress and Maximum Equivalent Strain both increase.

And I also attach the Ansys Workbench File and Animation File in the attachment please find it.