Finite Element Analysis of Wire Bending Operation using ANSYS Workbench

Objective : Perform an analysis to simulate the bending of a wire using 3 different types of materials for the wire.

Geometry

Materials

For pipe were are goanna use three different materials

Copper Alloy NL

Aluminum Alloy NL

Magnesium Alloy NL

Contact Region

• Contact type: Frictional
• Co efficient of friction: 0.2
• Formulation: Augmented Lagrange
• Normal Stiffness factor: 0.1
• Update Stiffness Each Iteration
• Interface treatment : Add offset Ramped

Wire to Lever

Wheel To Wire

Joints

• Connection type: Body - Ground
• Type: Revolt

Mesh

• Patch Conforming Method for whole assembly with Tetrahedrons element

• Face size on the region of contact with element size 2.2mm

• Face size in region where pipe will experience maximum stress why bending type sphere of influence with radius 7mm and element size 0.5mm

Boundary condition

• Top end of the pipe is being fixed so that it shouldn\'t sliding why bending
• The wheel or die shouldn\'t while lever moves so the wheel is fixed
• Joint load is given to the lever

Type :rotation 0-140degree

Analysis setting

Post Processing

• Equivalent von mises Stress on a Wire
• Equivalent Elastic Strain on A Wire

Solution Output

Case1:Copper Alloy NL

Equivalent von mises Stress on a Wire(674.74MPa)

Equivalent Elastic Strain on A Wire(0.0032168)

Case2:Aluminum Alloy NL

Equivalent von mises Stress on a Wire(459.42MPa)

Equivalent Elastic Strain on A Wire(0.0052040)

Case3:Magnesium Alloy NL

Equivalent von mises Stress on a Wire(257.88MPa)

Equivalent Elastic Strain on A Wire(0.0057453)

Results & Comparsion

• Amoung these three Materials the Copper Alloy NL has the maximum stress and minimum strain, the higher the young\'s modulus the lower the strain
• Magnesium Alloy has the minimum stress but maximum strain which means deformation will be more because of less young\'s modulus
• Aluminum Alloy stays in between the magnesium alloy and copper alloy in material properties thats why it has either maximum or minimum stress or stain.