Week 4 -Wire Bending Challenge

Aim-

Perform an analysis to simulate the bending of a wire in ANSYS. You will have to use Copper Alloy (Non Linear), Aluminium Alloy (Non Linear) and Magnesium Alloy ( Non Linear) for the wire alone. You need to find out the Equivalent stress and Equivalent strain on the wire alone. Compare the results and submit a well formatted report on this

Procedure-

1) open the engineering data source and add the required material, in our case Copper Alloy (Non Linear), Aluminium Alloy (Non Linear) and Magnesium Alloy ( Non Linear) and exit

2) Click on geomrtry and import the given model, check for any abnormality, if not found close the geometry tab

3) click on model to open mechanical APDL , here rename the parts as wire, wheel and lever

click on wire and under details view, click on assigmnent to assign the matrials

4) go to Connections and rename them based on defination, now delete the connections between Lever-Wheel & Wheel-Wire, let only connection between Wire and lever be there, now duplicate this connection and flip the target and contact for this new connection, and remove the level from the contact and add wheels surfaces instead

now change the type to frictional, add friction coefficient of 0.2, formulation to augmented lagrange, normal stiffness to factor = 0.1, update each itetration , effects to add offset ramped effects

Add a body to Ground revolute Joint to lever 

5) For meshing insert a face sizing of 2mm for every contact face, and add a sphere of influence to the region where most bending or initial stress will be developed by defining a local co ordinate system

6) Under Static structural in analysis settings, add 8 time steps and for 1st step change the solver type to direct,week spring to program controlled , large deflection on, auto time stepping on, define by time, with minimum time step 0.01 and max as 0.2 and in output control click everthing to yes, for remaing 2-8 steps, autotime stepping on, define by time, large deflection on, minimum ttime step 0.1 and max as 1

add fixed support to wheel and wire end face , and add joint load of rotation from 20 degrres to 140 degree

7) in solution add Equivalent stress and Equivalent strain on the wire alone and hit solve