Week 4 -Wire Bending Challenge
Aim : To perform an analysis to simulate the bending of a wire in ANSYS.
Objective :
To 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.
Procedure :
Engineering data and material :
- Open engineering data.
- Go to general non linear material from engineering data sources.
- Add Copper Alloy NL, Aluminium Alloy NL and Magnesium Alloy NL to library.
Geometry :
- Import geometry.
- Check for abnormalities.
Model Setup :
- Open geometry and rename the components as Wheel, Wire and Lever.
- Assign Copper Alloy NL as material to Wire.
Contacts :
- Rename based on defination.
- Keep contact between Lever and Wire and delete other two contacts.
- Right click and duplicate the contact.
- Flip the duplicated contact.
- Create contact between Lever and Wire
- Create contact between Wheel and Wire
- Select both contacts and give following parameters
Joints :
- Create revolute joint for lever.
- Lever should be rotate about Z-axis.
Meshing :
- Insert method as tetrahedrons and select all components.
- Insert sizing of size 1.8 mm for faces in contact.
- Click on Bend surface of wheel and create coordinate system
- Give X-offset as 3 mm and Z-offset as -3 mm.
- Insert sizing for Wire
- Go to mesh and set smoothing to Low
- Generate mesh
Analysis settings :
- For 1st time step
- For time step 2 to 8.
Fixed support :
- Create fixed suppport for Wheel and tip of wire.
Joint load :
- Insert Joint load for revolute joint of type rotation.
- Give table values to rotate about Z-axis.
Solution :
Create output results for :
- Total deformation.
- Equivalent stress.
- Equivalent strain.
- Equivalent stress on Wire.
- Equivalent strain on Wire.
Results :
Case 1 : Wire Material as Copper Alloy NL
Equivalent stress on Wire :
Equivalent strain on Wire :
Case 2 : Wire Material as Aluminium Alloy NL
Equivalent stress on Wire :
Equivalent strain on Wire :
Case 3 : Wire Material as Magnesium Alloy NL
Equivalent stress on Wire :
Equivalent strain on Wire :
Comparison of Results :
| Sr. No. | Results | Copper Alloy NL | Aluminium Alloy NL | Magnesium Alloy NL |
| 1 | Maximum Equivalent Stress (MPa) | 328.514 | 313.62 | 257.11 |
| 2 | Minimum Equivalent Stress (MPa) | 0.005343 | 0.003468 | 0.002164 |
| 3 | Maximum Equivalent Strain | 0.00306 | 0.00448 | 0.00573 |
| 4 | Minimum Equivalent Strain | 7.9387 E-08 | 7.8881 E-08 | 7.9150 E-08 |
Conclusion :
- The values of each case are different as the non-linear material applied has different properties.
- The stress values are high in case of Copper Alloy Non-linear material and least in Magnesium Alloy Non-Linear material.