Wire Bending Challenge

Challenge : To run a simulation of bending a wire using a static structural system for
three different cases.

The Wire Bending model first imported to ansys and then material was set to structural steel for Wheel & Lever and Copper Alloy NL ( Case 1 ), Aluminium Alloy NL ( Case 2 ), Magnesium Alloy NL ( Case 3 ) for Wire.

Connections Settings :

Contact set by default are to be deleted and a new contact are setup. One contact between the wire and the lever and another contact between the wheel and the wire.

we have set frictional contact of coefficient 0.2 between them and the rest of the details
are shown below.

Joints :

Mesh Setting :

1. By Using Tetrahedron method for whole body we making sure that only linear equestions will form and they will take less computational time with less errors.

2. The portion where is going to bend is given a cordinate of 3mm in x and z direction in each case. Rest setting as by default only.

3. Face sizing given to wire and wheel with sphere of influence type of radius 7mm of element 0.8mm

4. Thereafter a face sizing of 2.2 mm between lever and wire.

Generated Meshing :

In Mesh Quality tab Smoothing set to low. and making sure that we are in problem limit for this acadmic version of ansys.

Analysis Settings :

Fixed Supports

Wheel Centre And Bar top face is fixed.

Joint Setting

Problem is divided in 8 step, so we are giving 8 rotations only.

For 1st Step These settings are applied

For 2nd to 8th step these settings are applied

Note : For all Cases above settings are same Except material assigning is different for Wire in each case

Running the simulation and getting proper results

Simulation Result :

Equivalent Stress - Case 1

Equivalent Stress - Case 2

Equivalent Stress - Case 3

Equivalent Elastic Strain - Case 1

Equivalent Elastic Strain - Case 2

Equivalent Elastic Strain - Case 3

Result :

Case 1- Copper Alloy NL

Case 2- Aluminium Alloy NL

Case 2- Magnesium Alloy NL

Conclusion :

A stiff material has a high Young\'s modulus and changes its shape only slightly under elastic loads (e.g. diamond). A flexible material has a low Young\'s modulus and changes its shape considerably (e.g. rubbers)

Amongst all these material Copper Alloy NL, Magnesium Alloy NL, Aluminium Alloy NL, Copper alloy NL has highest Youngs Modulas, thus giving a resistance in the form of stress when load is applied.

# Avg Equivalent elastic strain in ( mm )

Copper Alloy NL ~5.33mm < Aluminium Alloy NL ~6.14mm < Magnesium Alloy NL ~6.7mm

Less Strain in Copper alloy NL Wire , Max Strain in Magnesium Alloy NL Wire

# Avg Equivalent stress ( Pa )

Copper Alloy NL ~4482.143 > Aluminium Alloy NL ~2818.109 > Magnesium Alloy NL ~1823.681

Less Energy is required to Bend Magnesium Alloy NL Wire , Max Energy is required to bend Copper Alloy NL Wire

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