Week 3 Sheet metal Bending challenge
Report week3 Sheet metal Bending challenge
Aim: Simulate the process of sheet metal bending in the following 3 cases.
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.
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.
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.
Procedure:
Import geometry:
Material: we are going to use the following materials in this report
Structural steel
Aluminum Alloy NL
Aluminum Alloy 1199
Copper Alloy NL
Magnesium Alloy NL
Contact:
Mesh:
Mesh size of punch and die are 4mm, plate mesh size is 1mm with Tetra mesh, contact area is 1mm
Analysis setting
Displacement
case 1
Result:
Aluminum Alloy 1109
Equivalent stress
Equivalent elastic strain
Total Deformation in Y direction
Copper Alloy NL
Equivalent stress
Equivalent elastic strain
Total Deformation in Y direction
Magnesium Alloy NL
Equivalent stress
Equivalent elastic strain
Total Deformation in Y direction
case 2:
change material to Aluminium Alloy, change the friction coefficient to 0.19
Equivalent stress
Equivalent elastic strain
Total Deformation in Y direction
case 3: refine the mesh, change plate mesh size and contact area mesh size to 0.75mm
Material is Al Alloy NL
Equivalent stress
Equivalent elastic strain
Total Deformation in Y direction
Conclusion:
1. From case 1, the maximum deformation of Copper Alloy NL is the highest, Magnesium Alloy NL sheet metal is the lowest. The maximum equivalent elastic strain of Al Alloy 1199 sheet is the lowest, Magnesium Alloy NL is the highest. The maximum equivalent stress of Al Alloy 1199 is the lowest, Magnesium Alloy NL is the highest.
2. From case 2, the maximum equivalent elastic strain, maximum v-m stress are higher than case 1 Al Alloy 1199. But maximum deformation is less than case 1 Al Alloy 1199.
3. From case 3, after mesh refining, the result is minor different but close to real result.