Week 3 Sheet metal Bending challenge

ANSYS CHALLENGE 3: SHEET METAL BENDING CHALLENGE

AIM:
To evaluate the simulation for sheet metal bending process with three different materials, friction coefficient, and refine th
mesh.

OBJECTIVE:

Evaluate the result for the sheet metal bending process in three cases:
Case1: Compare the result for three different materials Aluminium alloy 1199, Copper Alloy NL, Magnesium Alloy NL, and find out
equivalent stress, equivalent strain in the Y direction.
Case 2:With material Aluminium alloy change the friction coefficient factor to 0.19 and compare the result with case 1.
Case 3: Refine the mesh on the plate with Aluminium alloy and compare results.

MATERIALS PROPERTIES:
Aluminium Alloy 1199

Fig 2: Changing properties value for aluminum alloy 1199

Copper Alloy

Fig 3: Properties of Copper Alloy

Magnesium Alloy

Fig 4: Properties of magnesium alloy

SIMULATION SETUP
Import the geometry in the geometry module and checking any damages or improper surfaces of the sheet any opening the geometry in the mechanical module.

Fig 5:
Sheet metal geometry Geometry
Renaming each part of the geometry as punch, die, and sheet, so it ill easy to call the function of each part.

Fig 6: Changing the name of geometry
Connections
For the movement of the punch on the sheet and for the frictional moment the connection is provided to them two contacts are
given.

1) Frictional - Punch to sheet
Selecting contact with 3 faces of punch and 1 face of the sheet as target body.

Type: Frictional.
Frictional coefficient: 0.1.

behavior:Auto asymmetric.
Formulation: Augmented Lagrange.
Interface treatment: Add offset, Ramped effects.

Fig 7: Contacts punch to sheet

2) Frictional: Sheet to die
Selecting contact with 1 face of sheet and 7 faces of the die as target body.
Type: Frictional.
Frictional coefficient: 0.1.
behavior:Auto asymmetric.
Formulation: Augmented Lagrange.
Interface treatment: Add offset, Ramped effects.

Fig 8: contact sheet to die

Mesh
This geometry has the face to the sheet, die, and punch so the mesh will be varying to each part differently, overall mesh on thegeometry is the default, but for the die and punch the boy selection is done for both with the mesh size 4mm as selecting body sizing.

Fig 9: 4mm mesh on punch and die
For body sizing 2 has been selected for a sheet with 1mm size and the body sizing 3 selected for the faces of die and sheet appro 10 faces.

Fig 10:10 faces 1mm mesh size
And the sheet is a solid part that can be mesh with tetra mesh and it can be done by the selecting insert batch conforming method.

Fig 11:Tetra Mesh method for sheet
As the setting up the mesh on the whole geometry, the mesh has been generated on the geometry.

Analysis setting

Setting up the analysis settings for the simulation at 10 steps with the end time 10s, with the

solver type: direct.

The process for this simulation will act like the punch will press the sheet and will love upwards direct after bending it and the die will be a stationer position for the whole process but it will lift up the sheet after the pressing process.

To evaluate the simulation in such settings displacement method to inserted for the simulation.
Displacement for punch selecting the top faces of the punch x,y, and z coordinates to be evaluated in the form of tabular data.

Fig 13:Displacement for punch

Displacement 2 for the sheet which will act as a moment in the z direct by selecting 2 sides' faces and calculating 2z direction is tabular data.

Fig 14: Displacement for sheet
And for the die displacement will act at steps 9 and 10 for minimum displacement to release the sheet at its position after bending and will calculate the result in tabular form for all three directions.

Fig 15: Displacement for die

Analysis Setting

Solution
After setting up the simulation for the punch, sheet, and die, we need to calculate the solution for:
Mandatory result: Equivalent (Non-mises) stress. Equivalent elastic strain. Directional deformation in (-Y) axis.

External Results: Equivalent stress 2 - to calculate the stress on the sheet.
Contact tool- Frictional and pressure on (Punch to a sheet).

Contact tool- Frictional and pressure on (Punch to a sheet).

Fig 16:contact tool 1

Contact tool 2 -
Frictional and Pressure (Sheet to die).

Fig 17:contact tool 2

And force reaction for boundary condition (displacement).

RESULTS

Case 1: For all three materials Aluminium Alloy 1199, Copper alloy NL, and Magnesium alloy NL
Aluminium Alloy 1199:The equivalent Von -mises stress:

Fig 18: Equivalent Von misses stress

Equivalent elastic strain

Fig 19: Equivalent elastic strain

Directional deformation

Von Mises stress in Sheet

Contact Status - punch to sheet

Contact Pressure - punch to sheet

Frictional Stress - Punch to sheet

contact 2 - Frictional - SHEET To DIE 

contact 2 Pressure - Frictional - SHEET To DIE 

Frictional Stress - SHEET To DIE

Reaction force 

Results comparison
Case 1: Comparison of the result for cases