International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 10 Issue: 10 | Oct 2023 www.irjet.net p-ISSN: 2395-0072
Design & Structural Analysis of Sheet Metal Bending Operation in
Ansys Workbench
Shubham Patil1, D.H.Nimbalkar2, Vikramsinh Mane3
1M.Tech Student Dept. of Mechanical Engg. College of Engineering Osmanabad, Maharashtra, India
2Professor Dept. Of Mechanical Engg. College of Engineering Osmanabad, Maharashtra, India
3Principal College of Engineering Osmanabad, Maharashtra, India
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Abstract -The sheet metal bending is an important sheets in flat pieces or coils and are measured by their thickness or
metal forming process in which sheets were securely clamped, gauge. Very thin pieces of metal are called foil or leaf and
stretched over rigid punches, and strain distributions thick metals are called plate. Some of the industries using
measured for different conditions of lubrication and punch bending machine as their process to produce their product.
form. In general, the development of strain in the various Figure 1 shows the actual setup of sheet metal bending
elements of a sheet was marked at some stage of the operation.
stretching by a discontinuous increase in er the algebraically
largest component.The sheet metal plate is modeled by using
modeling software catiav5. By using catia V5 software the
time required for producing the solid models and the
complicated process involved in the design and manufacturing
process can be easily minimized. So the modeling of the sheet
metal plate assembly is done by using CATIA V5. Later this
CATIA modal is imported to ANSYS WORKBENCH 2021 for
analysis work. ANSYS WORKBENCH 2021 is the latest software
used for simulating the different forces acting on the
component and also calculating and viewing the results. By
using ANSYS WORKBENCH 2021 software reduces the time Fig -1: Sheet metal bending operation
compared with the method of mathematical calculations by a
human. ANSYS WORKBENCH 2021 transient structural In our project work bending test is done by using press
analysis work is carried out by considered three different non- brake machine. In this test, bottoming u-die bending is
linear materials namely aluminum alloy, magnesium alloy and selected since there has many types of die in bending
structural steel and their relative performances have been process. 30 degree of die angle is functioning as a reference
observed respectivelyis suggested as best material for sheet angle and this project only considers the different sheet
metal plate bending. materials and bending directions.
Key Words: Sheet Metal, Bending operation, CatiaV5, 1.1 Classification of basic sheet forming processes
Ansys2021
1. INTRODUCTION
There have many applications using sheet metal such as
ductwork, airplane wings, car bodies, medical tables and
storage units, steel sheets, tubing and signs. It is one of the
important forms used in metal industry and it can be bent
into a variety of shapes for industrial application. Bending is Fig -2: Classification of sheet forming processes
a manufacturing process that is mostly used to produces a V-
shape, U-shape, or channel shape along a straight axis in 1) Forming: Sheet metal forming involves forming and
ductile materials, commonly used equipment includes box cutting operations performed on metal sheets & strips. In
and pan brakes, brake presses, and other specialized this process the surface area-to-volume ratio of the starting
machine presses. Different types of products that are made metal is relatively high. Alsoit include punch & die that are
with this are boxes such as electrical enclosures and used to deform the sheets.
rectangular ductwork. Forming is a mechanical process
involves shaping material in the solid state whether the 2) Bending: In this, the sheet material is strained by punch
material is a continuous solid or powder. Sheet metals come to give a bend shape (angl e shape) usually in a straight axis.
© 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 752
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 10 Issue: 10 | Oct 2023 www.irjet.net p-ISSN: 2395-0072
3) Deep (or cup) drawing: In this operation, forming of a 7. Equivalent stress, total deformation, maximum principal
metal sheet into a hollow or cup shape is performed by stress, and maximum principal elastic strain are the
stretching the metal in some regions. In this process a blank- parameters.
holder is used to clamp the blank on the die, while the punch
pushes into the sheet metal. The metal sheet is drawn into 3. Selection of Material
the die hole taking the shape of the cavity.
An analysis was conducted for three different materials of
4) Shearing: In this operation cutting of sheets by shearing the sheet metals namely
action.
1. Aluminum Alloy 1199
1.3 Objectives
Aluminum alloy is aluminum based. With a minimum of
1. To study and perform structural analysis on sheet metal 99.99% aluminum, it is the purest and least alloyed of the
with different material and frictional coefficient. commercial aluminum alloys. It is gentle and incorrect for
machining. At the same time, it possesses excellent corrosion
2. To prepare the geometrical model for the varied resistance, electrical conductivity, and thermal conductivity.
geometrical parameter like sheet thickness, size of sheet
etc. 2. Copper Alloy
3. To identify the region of stress concentration and Copper and copper alloys are one of the fundamental
variation material of sheet metal shall be plotted and companies of industrial metals. They provide a huge variety
appropriate conclusion shall be drawn. of properties, consisting of high-quality electric and thermal
conductivity, notable corrosion resistance, good strength
4. To calculate the equivalent stress, deformation and and fatigue resistance, and appearance. They can be readily
internal energy absorption for different materials. worked, brazed and welded.
2. Methodology 2. Magnesium Alloy
The design of sheet metal while bending operation had to Magnesium alloys are mixtures of magnesium with other
choose the variety of parameters which include different metals (called an alloy), often aluminum, zinc, manganese,
types of sheet materials, size of sheet etc. Hence it is silicon, copper, rare earth, and zirconium. Magnesium alloy
analyzed some of the sheet while bending in v shape by trends have historically been pushed via way of means of
varying some all of the parameters like plate thickness, aerospace enterprise necessities for light-weight substances
various sheet material, sizes of sheet compare to the to perform below more and more stressful
numerical analysis on various loading condition, finding conditions.Magnesium alloys have constantly been appealing
various stresses on it & total deformation. to designers because of their low density, handiest thirds
that of aluminum.
The proposed work include following step.
4. Bending Force Calculations
1. We have Studied literature review on various work
reported.
2. Selecting different sheet materials are available in the
market:
a) Aluminum Alloy 1199
b) Copper Alloy
c) Magnesium Alloy
3. Bending Force calculation is done using different
formulas.
4. The geometrical model shall be prepared for the varied
geometrical parameter like sheet thickness, size of sheet
etc.
5. CAD Model is prepared using various tool – catia version- Fig -3: Bend Allowance
V5 i.e. extrude, revolve, mirror etc.
6. The evaluation outcomes acquired shall assist to become 1. For aluminum Sheet
aware of the area of stress concentration and variation
material of sheet metal shall be plotted and appropriate A sheet metal material of alluminum alloy having tensile
conclusion shall be drawn. strength 115 Mpa having thickness of plate 5 mm, length 150
© 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 753
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 10 Issue: 10 | Oct 2023 www.irjet.net p-ISSN: 2395-0072
mm, width 50 mm, is subjected to bending in v-die with
opening of angle 110 degree.
Ultimate tensile strength (S) =2400 Mpa
Length of sheet metal plate l = 150 mm
Width of plate w = 50mm
Thickness of plate t = 5mm
Bending radius R= 5 mm
Bend Allowance (Ba) = × (R + K×T) × A
= × (5 + 1.33×5) × 110
Fig -5: Imported assembly files in ANSYS
Ba = 36.5868mm
Total length, L = 50+50+36.58 5.3 Meshed Model
L = 136.58 mm
The mesh metric is applied to identify the factors in line with
Bending force (Fb) = their quality. The best of the mesh quality is appropriate as
maximum of the factors lie inside a high variety of range 0.8-
Where,
1.0.
F=Bending Force, Ts= Tensile Strength of sheet
metal, D= Dia opening diemension, K=1.33, The sheet metal and faces of punch and die which comes in
contact with a sheet, the sheet has only meshed with an
element size of 1mm. different components have meshed
Bending force, (Fb) =
with an detail length of 4mm.
= 10444.95N
Fb = 10.44KN
Same calculations is done for other materials
1. For Copper Sheet
Fb = 15.44KN
1. For Magnesium Sheet
Fb = 25.43KN
5. Modeling & FEA Analysis of Sheet Metal
5.1 Modeling of Punch & Dia Fig -6: Mesh Model
The setup of die, punch and sheet metal is drawn in the catia
V5 software which is shown in Figure 4 5.4 Analysis Results for Alluminum Alloy 1199
A. Equivalent elastic strain
Fig -4: Catia Model
Fig -7: Equivalent elastic strain for Aluminium Alloy
5.2 Ansys Geometry
Figure 5 shows the assembly file that is imported into the
ansys workbench for the purpose of analysis and simulation.
© 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 754
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 10 Issue: 10 | Oct 2023 www.irjet.net p-ISSN: 2395-0072
B. Equivalent stress C. Total Deformation
Fig -8: Equivalent stress
C. Total Deformation Fig -12: Total Deformation
5.6 Analysis Results for Magnesium Alloy
A. Equivalent elastic strain
Fig -9: Total Deformation
5.5 Analysis Results for Copper Alloy
A. Equivalent elastic strain Fig -13: Equivalent elastic strain for Magnesium Alloy
6. RESULT & DISCUSSION
In this work methodology to perform static structural
analysis on the sheet metal bending model with different
materials considering the different frictional values to find
out the equivalent von mises stress, total deformation and
Equivalent Elastic Strain results.
Hence the material has been defined for all the three
cases.
Fig -10: Equivalent elastic strain for Copper Alloy
Hence the connections were defined to the Sheet Metal
B. Equivalent stress Bending Model.
Hence the model has been solved for Von-Misses Stress,
Equivalent Elastic Strain, Stress Intensity, Contact Tool
and Directional Deformation by applying appropriate
boundary conditions.
Fig -11: Equivalent stress
© 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 755
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 10 Issue: 10 | Oct 2023 www.irjet.net p-ISSN: 2395-0072
Table -1: Obtained Reslults 3) Aluminum alloy is easily formed and the coefficient of
friction between contact surfaces was raised from 0.1 to
Aluminum Magnesium 0.19 for the second aim. However, it had little imact at the
Title Copper Alloy
Alloy Alloy outcome.
Values Min Max Min Max Min Max
4) We have concluded that, the Aluminium Alloy 1199 is
Equivalent 1.5605 63.18 3.0537 135.6 3.101 89.05 preferable when compared to other two cases, Cause the
Stress e-12 9 e-12 2 1e-12 stress and the deformation occured is very less when
- 2.224 - 2.848 - 2.5285
compared to the other two cases.
Deformatio
n (mm) 12.449 11.647 9 11.31
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© 2023, IRJET | Impact Factor value: 8.226 | ISO 9001:2008 Certified Journal | Page 756
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 10 Issue: 10 | Oct 2023 www.irjet.net p-ISSN: 2395-0072
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