BENDING OF WIRE USING ANSYS WORKBENCH

AIM:

To perform an structural analysis to simulate the bending of a wire considering three different case setups and compare their results.

STRUCTURAL ANALYSIS:

• Structural analysis is the process of calculating and determining the effects of loads and internal forces on a structure or an object.

NEED FOR STRUCTURAL ANALYSIS:

• Structural Analysis is particularly important to understand the load paths and the impacts the loads have on engineering design.
• It allows engineers to ensure a piece of equipment or structure is safe for use under the estimated loads it is expected to withstand.

CASE SETUP: 1

WIRE MATERIAL: COPPER ALLOY NL

MATERIAL PROPERTIES

PROCEDURE FOR IMPORTING THE MODEL:

• Assign the material type to the model to be imported using the tool Engineering data-Edit-Engineering data sources
• Import the MODEL file using the tool Geometry-import.

PROCEDURE FOR STRUCTURAL ANALYSIS:

• Update the model to work on the model for structural analysis

• Under Model-geometry assign the name for setup based on their application.
• Under connection create contact1 between the lever and wire and contact2 between wire and wheel.
• Under connection create a revolute joint for the lever to bend the wire.

CONTACT 1 CONTACT 2

• Mesh the contact faces between wire and lever with a mesh size of 2.2mm and the contact faces between the wire and wheel with a mesh size of 0.8mm
• Setup the mesh method as tetrahedrons.

MESHED MODEL

• Under static analysis in analysis setting sub menu setup the controls as shown in the image below

• Under analysis setting create a fixed support for the wheel by selecting its center hole followed by create another fixed support at the end of wire to prevent sliding.
• Under analysis setting create a revolute joint for the lever and specify the rotation angles as mentioned below

• Insert the von-mises stress, elastic strain for the wire and then press f5 to solve.

RESULTS:

VON-MISES STRESS

ELASTIC STRAIN

CASE SETUP: 2

WIRE MATERIAL: ALUMINIUM ALLOY NL

MATERIAL PROPERTIES

RESULTS:

VON-MISES STRESS

ELASTIC STRAIN

CASE SETUP: 3

WIRE MATERIAL: MAGNESIUM ALLOY NL

MATERIAL PROPERTIES

RESULTS:

VON-MISES STRESS

ELASTIC STRAIN

COMPARISION OF RESULTS:

• Young\'s modulus is equal to the ratio of stress and strain. Hence strain is inversely proportional to young\'s modulus. Here the case setup:3 material has the lower young\'s modulus than other two case setup material, so it must have higher strain and from the result the Magnesium Alloy NL has the higher elastic strain value i.e., 0.0053082
• Stress is independent of young\'s modulus. The yield strength for Copper Alloy NL and Aluminium Alloy NL is same but greater than Magnesium Alloy NL. Yield strength is the stress at which the material begin to deform. Hence from the result Copper Alloy NL and Aluminium Alloy NL has higher equivalent stress when compared with Magnesium Alloy NL.

CONCLUSION:

Thus structural analysis to simulate the bending of a wire considering three different case setups has been performed and the results were compared.