Week 4 -Wire Bending Challenge

Objective: To perform an analysis to simulate the bending of a wire in ANSYS using 3 different materials (Copper Alloy NL, Aluminium Alloy NL, Magnesium Alloy NL) and its results are compared.

1. Geometry:

2. Material data:

3. Case setup and settings

a. Coordinate system:

Along with the basic coordinate system, an additional coordinate system is added near the bending notch for the smoothening simulation and for mesh sizing reference.

b. Connections:

i. Contacts:

Frictional contacts are made to the wire to the lever and from wheel to wire.

ii. Joints:

A revolute body to ground is made with Z axis as reference, (as shown in the fig. below).

c. Mesh

face Sizing is provided at the lever and wire. Specific sizing is done at the notch where the bend is initiated with the help of coordinate system. Tetragonal mesh is made with the following specifications and sizing.

d. Structural Input details:

i. Analysis setting: ii. Fixed supports:

iii. Rotation joint:

Revolute joint is made with respect to the Z axis. The lever is made to rotate around the wheel about 140° for a sequential 8 steps with an interval of 20° and is kept at the same for the last 2 steps.

e. Solution:

(For demonstration, case 1 is presented)

i. Total deformation:

ii. Equivalent strain on wire:

iii. Equivalent stress on wire:

4. Result:

(Max values are considered)	Total Deformation- (mm)	Equivalent stress on wire - (MPa)	Equivalent strain on wire - (mm)
Copper Alloy NL	262.64	343.04	0.00315
Aluminium Alloy NL	262.64	314.03	0.00441
Magnesium Alloy NL	262.64	267.11	0.00594

The value of density of materials are, 8300 kgm^-3,2700kgm^-3,1800kgm^-3 respectively.

The value of yield strength of mentioned materials are, 280MPa,280MPa,193MPa respectively.

5. Conclusion:

• The Deformation remains constant as the applied force and other factors except the material is the same.
• The sequence of density and yield strength in ascending order are as follows:
  • Cu>Steel>Al>Mg -- Density
  • Cu~Al>Steel>Mg -- yield strength
• As the density increases, the stress value increases and strain value reduces.
• Higher the yield strength, greater the tendency to resist the deformation, hence higher stress.
• Here, Copper shows higher stress values and magnesium shows less.
• Strain for copper is less and higher for magnesium.

Animations are attached for reference:

(Case1)