• Prafful Kumar Kubde
• Dr. PRABHASH JAIN
• Dr. ROHIT RAJVAIDYA

Sheet metal forming is a vital process in modern manufacturing, extensively used in the automotive and aerospace industries to create components with precise dimensions and minimal defects. This technique involves shaping a flat sheet of metal into a desired form using a punch and die, allowing for the production of complex geometries with high accuracy. In this research, the energy absorption characteristics of copper alloy, Al 1100, and Al 5083 sheet metals with varying thicknesses were investigated through simulations performed using the ANSYS Explicit Solver workbench. The CAD modeling and finite element analysis (FEA) were carried out in ANSYS DesignModeler, focusing on key performance metrics such as Equivalent Stress (Von-Mises Stress), Total Deformation, Internal Energy, and Shear Stress. To enhance the forming process, the study applied the Taguchi Response Surface Method to optimize the finite element model, concentrating on critical variables like die length and die angle. The optimization process aimed to improve the accuracy and efficiency of the sheet metal forming process by refining these parameters. The simulation results provided detailed insights into stress distribution, internal energy patterns, and deformation behavior for the different materials and thicknesses studied. The findings from this research offer a comprehensive analysis of the performance of copper, Al 1100, and Al 5083 sheet metals under various forming conditions. By understanding these characteristics, the study contributes to the development of more effective and efficient sheet metal forming processes, which are crucial for meeting the high standards required in industrial applications, particularly in the automotive and aerospace sectors.

FEA, Sheet Metal Forming, V-Bending Process, Copper Alloy, Al100, Al 5083, ANSYS

"OPTIMIZATION OF V-BENDING PROCESS USING ANSYS", International Journal of Emerging Technologies and Innovative Research (www.jetir.org), ISSN:2349-5162, Vol.11, Issue 12, page no.f231-f241, December-2024, Available :http://www.jetir.org/papers/JETIR2412526.pdf

"OPTIMIZATION OF V-BENDING PROCESS USING ANSYS", International Journal of Emerging Technologies and Innovative Research (www.jetir.org | UGC and issn Approved), ISSN:2349-5162, Vol.11, Issue 12, page no. ppf231-f241, December-2024, Available at : http://www.jetir.org/papers/JETIR2412526.pdf