Wire Bending

In this following siimulation process wire bending simulation the material property of wire has been changed and their corresponding stress and strain on the wire has to be calculated and then corresponding results has to be compared as follows:

GEOMETRY:

Fig. Geometry of Wire bending Simulation

Since the mesh and the element quality and the corresponding Boundary conditions has to reamsin same only the material property of the wire will change.

MESH:(GRID GENERATION)

The Mesh is as follows:

Fig. Mesh Generation

• In the following mesh the the contact between wire and wheel where it will be more stress generated
• The mesh Generated is tetrahedron mesh
• THe contact mesh between wire and pulley with element size of 0.4 mm has been kept and the rest with an element size of 2mm respectively with Nodes of 22897 and 8987 elements

Fig. Element Quality

BOUNDARY CONDITION:

In the following Simulation he pulley is made to rotate with an angle of 140 degrees in followin 8 substeps as shown :

Fig. Boundary Condition

SOLUTION :

CASE 1: COPPER ALLLOY (NL)

Fig. Total deformation for Copper wire

Fig. Strain on Copper wire

Fig. Stress on Copper wire

CASE 2: ALUMINIUM ALLLOY (NL)

Fig. Aluminium Wire Deformation

Fig. Strain on Aluminium Wire

Fig. Stress on Aluminium Wire

CASE 3: MAGNESIUM ALLLOY (NL)

Fig. Total Deformation of Magnesium

Fig. Strain on Magnesium Wire

Fig. Stress on Magnesium Wire

CONCLUSION:

From the above result the deformation appears to remain unchange in all the cases respectively

Following stress and strain are tabulated as follows:

Sr No	CASE	STRAIN ON WIRE	STRESS ON WIRE (MPa)
1	COPPER	0.0049	393.01
2	ALUMINIUM	0.0053	339.58
3	MAGNESIUM	0.0091	384.35

• From the above table the stress generated is MAXIMUM for the Copper wire
• From the above table the stress generated is MINIMUM for the Aluminium wire
• Strain generated is Maximum for Magnesium wire
• Strain generated is Minimum for Coper wire
• Generally the strain generated should in aluminium should be less but due to mesh constraints it is near by copper otherwise aluminium has lower strain.