Wire Rolling

Objective:

To perform an analysis to simulate the bending of a wire in ANSYS. By using Copper Alloy (Non Linear), Aluminium Alloy (Non Linear) and Magnesium Alloy ( Non Linear) for the wire to find out the Equivalent stress and Equivalent strain on the wire alone

Procedure:

* Open ANSYS Work bench, from the analysis systems drop the Static structural in Project schematic.

* Select required material from materials, In our case we need Copper Alloy (Non Linear), Aluminium Alloy (Non Linear) and Magnesium Alloy ( Non Linear) For Wire.

* Import Geometry and open in design moduler to check the geometry. Open in Mechanical module and rename the parts for easy identification purpose.

* Select the contacts and rename them as per definition. Delete default contacts which are not required and Create contact between heel to wire and wire to lever as looks below.

* insert body to gound revolute joint and select the lever inside face for revoulution of lever.

* to produce mesh on model and to get accurate results on particular areas face sizing is required. for that on the wire will createa sphere influence area by creating new coordination system. genereate a sphere on wire with 8mm diameter. as shown below

* remaining wire and lever contact area face sizing with 2.2mm and generate mesh which appears as below.

* Below are the analysis settings we need for simulation, simuation takes place in 8steps, for the step 1 and step 2 to 8 below are the analysis required.

* Insert fixed support on wheel and wire end inside face to fix the wheel as constant.

* Insert joint load and select revolute joint give the tabular data for lever rotation as shown below.

* Insert Equivalent strain (wire) and Equivalent stress (stress) as outputssolutions and click on the solve button to initiate simulation

Results:

For Copper alloy NL

Aluminium Alloy (Non Linear)

Magnesium Alloy ( Non Linear)

Material Type	Equivalent strain on wire	Equivalent stress on wire
Copper alloy NL	0.00293 mm/mm	322.35 MPa
Aluminium Alloy (Non Linear)	0.00453 mm/mm	321.14 MPa
Magnesium Alloy ( Non Linear)	0.00587 mm/mm	263.57 MPa

Conclusion:

In Equivalent Strain point of on wire

Copper Alloy (N L)< Aluminium Alloy (N L) <Magnesium Alloy ( N L)

In Equivalent stress point of view

Copper Alloy (N L)> Aluminium Alloy (N L) >Magnesium Alloy ( N L).