FEA OF WIRE BENDING IN ANSYS
PROJECT OBJECTIVE:
To simulate the equivalent stress and strain of the bending of wire using 3 different materials namely,Copper Alloy (Non Linear), Aluminium Alloy (Non Linear) and Magnesium Alloy ( Non Linear).
MODEL:
MATERIAL:
The material properties of the material used are:
ALUMINIUM ALLOY NL
DENSITY:2770 kg/m3
YOUNG'S MODULUS:7.1e+10 Pa
BULK MODULUS:6.9e+10 Pa
POISSON'S RATIO:0.3
YIELD STRENGTH:2.8e+08 Pa
SHEAR MODULUS:2.6e+08 Pa
COPPER ALLOY NL
DENSITY:8300 kg/m3
YOUNG'S MODULUS:1.1e+11 Pa
BULK MODULUS:1.14e+11 Pa
POISSON'S RATIO:0.34
YIELD STRENGTH:2.8e+08 Pa
SHEAR MODULUS:4.1e+08 Pa
MAGNESIUM ALLOY NL
DENSITY:1800 kg/m3
YOUNG'S MODULUS:4.5e+10 Pa
BULK MODULUS:5e+10 Pa
POISSON'S RATIO:0.35
YIELD STRENGTH:1.9e+08 Pa
SHEAR MODULUS:1.6e+08 Pa
CONTACT DETAILS:
Contact type: frictional
friction coefficient:0.2
formulation:augmented lagrange
normal stiffness factor:0.1
interface treatment:add offset, ramped effects.
The 2 types of contact are:
1.wire to lever contact
2.wheel to wire contact
MESHING:
The mesh is refined along critical areas subjected to high stress.
A face sizing of 2.2 mm has been given and a 7mm sphere of influence with mesh of 0.8mm is being generated.
ANALYSIS SETTINGS:
No of steps: 8
solver type:direct
weak springs:program controlled
large deflection:on
auto time stepping:on
define by:time
min and max step size:0.002 and 0.2
JOINTS:
Fixed support is given to the tip of wire so that the wire does not move away.
A revolute joint is given to the lever.
RESULTS:
CASE1:
COPPER ALLOY NL:
STRESS:
VIDEO:
EQUIVALENT STRAIN:
VIDEO:
DEFORMATION:
CASE2:
ALUMINIUM ALLOY NL:
STRESS:
VIDEO:
STRAIN:
VIDEO:
CASE3:
MAGNESIUM ALLOY NL:
STRESS:
VIDEO:
STRAIN:
VIDEO:
CONCLUSION:
It can be seen that the wire experiences maximum stress in the beginning and near the bending areas and the stress gradually becomes constant.
Since copper experiences the max stress, it provides more resistance to bending and hence is the least favourable material.
Magnesium alloy case experiences the most strain.
Hence MAGNESIUM is the most favourable material.