Week 4 -Wire Bending Challenge
objective: To perform wire bending operation in Ansys wrok bench
geometrical design: we are having 3D geometry of wire bending simulation model. This model consist of 3 main parts named as support, metal wire and lever. This geometry look like this;
material properties
For the wire alone 3 different material considered for an operation other parts material kept as structural steel only, these material having various mechanical property which are stated below:
problem statement: The wire is kept fixed in the support.roller will be applied with a certain rotation. will cause the wire to bend in such a way that we will get the required shape. when the lever will be applied with certain rotation. wire will undergo permanent deformation and stress will be generated in certain regions. we will consider 3 different material for this operation and will observe deformation, stress and strain at the end of simulation , we will compare all 3 result obtained.
local co-ordinate system:
for mesh refinement one new local co-ordinate is created. this is where the local co-ordinate is created:
mesh model:
mesh refinement at local co-ordinate
spare radius: 7.00mm
element size: 0.8mm
Boundary condition:
contact: for this analysis 2 friction contacts applied to various bodies of model with friction co-efficient of 0.2
joint: one revolute(body to ground) joint is created at the hole of lever.
fixed support: one enf of the wire is kept as fixed
loading and analysis setting
The whole analysis is divided in a total of 8 steps initial time step:
main time step: 1e-002
Max time step: 0.2s
the revolute joint is applied with rotation during 8 steps
Analysis settings:
post processing:
case1: copper alloy NL
total deformation
equivalent elastic strain
equivalent stress
case2: magnesium alloy NL
total deformation
equivalent elastic strain
equivalent stress
case3: aluminium alloy NL
total deformation
equivalent elastic strain
equivalent stress
Post process result
summary:
result and conclusion :
1) Max equivalent elastic strain is higher in magnesium alloy
2) max equivalent stress is same in copper alloy and aluminium we can conclude that the magnesium alloy will take less load for bending and copper will take higher load in bending .we can observe high stress at curves where there is actual bend.