Static Structural Analysis of the Wire Bending Operation using Ansys

Objective - To perform an analysis to simulate the bending of a wire by assigning different materials to the wire and analyze the Equivalent Stress and Equivalent Strain acting on the wire in each case.

Case 1 - Copper Alloy (Non Linear)

Case 2 - Aluminium Alloy (Non Linear)

Case 3 - Magnesium Alloy ( Non Linear)

Procedure -

Create Static structural analysis and in engineering data select the material structural steel for other components of geometry and Copper Alloy (Non Linear), Aluminium Alloy (Non Linear) and Magnesium Alloy ( Non Linear) for wire in different cases.

Structural Steel.

Case 1 - Copper Alloy (Non Linear).

Case 2 - Aluminium Alloy (Non Linear).

Case 3 - Magnesium Alloy ( Non Linear).

Import the geometry and check in SpaceClaim for any irregularities.

Then open Ansys mechanical and rename the geometry as Wheel, Lever and Wire then assign the structural steel material to Wheel and Lever and Copper Alloy (Non Linear), Aluminium Alloy (Non Linear) and Magnesium Alloy ( Non Linear) for wire in different cases.

Contacts - two contacts created in the whole setup with frictional type with friction coefficient of 0.2, formulation set to Augmented Lagrange, Normal stiffness to factor and value for the factor set to 0.1, update stiffness for each iteration and interface treatment is set to Add offset, Ramped effects.

Contact Frictional - Wire to Lever.

Contact Frictional - Wheel to Wire.

Revolute Joint is created for the lever it is ground to lever revolute joint.

Mesh - in mesh the whole geometry first we use the method i.e patch conforming method and method set to tetrahedrons.

Mesh - Face Sizing option use for meshing the lever cylinder outer surface and wire with 2mm element size.

Mesh - Face Sizing A coordinate system is defined at the filleted surface of the wheel with an offset of 3mm and -3mm in the X and Z directions respectively. A face size of 0.8mm is defined for the regions lying in a 7mm radius around the sphere center of this coordinate system.

The rest of the assembly mesh with the default mesh.

Analysis Settings - The simulation runs for 8 steps. So, the number of steps is set as 8.

The first step solver type is direct, large deflection set to on and defined by time. Initial time step set to 0.1s, Minimum time step set to 1e-2s and Maximum time step set to 0.2s. In Output control set all output to yes.

The second step to eight step solver type is direct, large deflection set to on and defined by time. Carry over time set to on, Minimum time step set to 1e-2s and Maximum time step set to 1s. In Output control set all output to yes.

Fixed Support - the wheel provides fixed support to constrain the movement of the wheel.

Fixed Support - the wire face provides fixed support to stop it moving out from the wheel.

Joint - Rotation - Lever is provided with a rotation of 140 degree.

Run the simulation and results obtained.

Result - The analysis runs successfully and results obtained.

Case 1 - Copper Alloy (Non Linear).

Equivalent Stress Max - 329.64 Mpa

Equivalent Strain Max - 0.0030257 mm/mm

Case 2 - Aluminium Alloy (Non Linear).

Equivalent Stress Max - 320.81 Mpa

Equivalent Strain Max - 0.0045872 mm/mm

Case 3 - Magnesium Alloy ( Non Linear).

Equivalent Stress Max - 264.17 Mpa

Equivalent Strain Max - 0.0058864 mm/mm

Conclusion -

• The equivalent stress is maximum for Copper Alloy wire and minimum for Magnesium Alloy wire.
• The equivalent strain is maximum in Magnesium Alloy wire and minimum inCopper Alloy wire.

Google drive link - https://drive.google.com/file/d/1XYi8sS4VUoH77UjD_YH0UZjbzz4s2plx/view?usp=sharing