Week 4 -Wire Bending Challenge

WIRE BENDING CHALLENGE

Objective:-

In this challenge, we have to perform an analysis to simulate the bending of a wire in ANSYS. We have to use the Copper alloy ( NL), Magnesium alloy ( NL), and Aluminum alloy ( NL) as materials for the wire alone. we need to find out the Equivalent stress and Equivalent strain for the wire alone and compare the results.

Procedure:-

1. First, we need to add the materials from the Engineering materials, we have added Copper alloy(NL), magnesium alloy ( NL), and Aluminum alloy ( NL) as materials.

2. Then we import the model into Ansys, import the model, and open it in the space claim to check for any geometry errors.

                                                                        Fig1. Given Model

3. Then we assign the required connections to the model.

4. We have assigned frictional contact between wire and lever.

                                              Fig 2. Frictional contact Between wire and lever

5. Then we assign Frictional contact between Wire and Wheel.

                                                          Fig 3. Frictional contact between wire and wheel.

6. Both contacts are given a Frictional coefficient of 0.2.

7. A revolute Joint is given between the ground to the lever.

                                                          Fig 4. Revolute Joint between ground to the lever.

8. Then we have to mesh the model using tetrahedrons in Patch conforming method.

9. Then we use Face sizing for the wire to mesh the wire with an element size of 2.2 mm.

10. Then we use Face sizing of type sphere of Influence with sphere radius of 7.0 mm and element size of 0.8 mm.

11. After doing meshing, we provide analysis settings to the model.

                          Fig 5. Analysis settings

12. And then we provide fixed supports and solve the model

Results:-

Results are calculated only for wire alone

1. Copper Alloy (NL)

                                                     FIG 6.Equivalent stress ( Copper Alloy (NL))

                                                   Fig 7. Equivalent strain (Copper Alloy (NL)) 

2. Magnesium Alloy ( NL)   

                                                       Fig 8.Equivalent stress ( Magnesium alloy (NL))

                                                              Fig 9. Equivalent strain (Magnesium alloy (NL))

3. Aluminum alloy (NL)

                                                       Fig 10.Equivalent stress (Aluminum alloy (NL))

                                                  Fig 11. Equivalent strain ( Aluminum alloy (NL))

Comparison:-

                                              Copper Alloy ( NL)                    Magnesium Alloy ( NL)         Aluminum alloy (NL)

Equivalent stress                            326.02                                  253.29                             314.1

Equivalent strain                          0.0029734                              0.0056365                       0.0044841

Conclusion:-

From the above table, it is clear that Copper alloy has maximum stress than other alloy materials because copper alloy has a higher young's modulus.