Week 4 -Wire Bending Challenge

Aim-

For this project we will have to perform an analysis to simulate the bending of a wire in ANSYS. We will have to use Copper Alloy (Non Linear), Aluminium Alloy (Non-Linear), and Magnesium Alloy (Non-Linear) for the wire alone. We need to find out the Equivalent stress and Equivalent strain on the wire alone.

Procedure-

• We have to first start as new project in the ansys workbench and select the proper material for the weld joint plate.
• Here material has been specified in the project so we will select materials as per case.

• Now we have to import the model for that right click on the geometry tab and hit import>>then select the file from saved location and hit ok.

• Now we have to open mechanical Model and wait for a while till our model loads.
• For wire select material as copper alloy NL.
• We have to now remane the parts name and the proceed further for connections.

Connections-

• Now we have to delete the two old connections and then need to duplicate connections.
• Now for first connection we keep frictional contact from wire to lever, (right click on connection and select rename based on connection).

• Now for duplicated contact we have reverse the connections and and select the contact as lever and target as wire.

• As our lever is going to rotate to bend the wire we need to define a revolute joint there.

Mesh-

• For meshing first we create the patch method to it, to do so right click on mesh>>insert>>method>>select all components and in type select tetrahedrons.

• Now we have to insert sizing for refined mesh to wire (here I have done meshing for copper alloy NL wire only since solution was not convering). To do So right click on mesh>>insert>>sizing.

• But for rest two materials I have selected total 4 surface refer below snap.

• Now for get proper result for bending we need to refine the mesh in area near wheel cutout, for that we have to create a new co-ordinate, near wheel cutout fillet & also need to do X & Z as 6mm and -3mm respectively, as shown in snap.

• For mesh right click on mesh>>insert>>sizing, refer below snap for reference.

Mesh for copper alloy NL

Mesh for Aluminium alloy NL & Magnesium alloy NL

Analysis setting-

• Go to analysis setting and set number of set as 8 and refer below setting for 1st step, Keep all output parameters ON.

• For 2 to 8 refer below snap

• Now we have to apply fixed support to wheel and wire as shown in snap.

• Now we have to apply joint load to lever bottom refer below snap,

Solution-

• Now for stress right click on the solution>>insert>>stresses>>equivalent (von-Mises).
• Now for strain right click on the solution>>insert>>strins>>equivalent (von-Mises).

Results-

1. Equivalent Stress on Wire-

Copper Alloy NL-

Aluminium Alloy NL-

Magnesium Alloy NL-

2. Equivalent Elastic Strain-

Copper Alloy NL

Aluminium Alloy NL-

Magnesium Alloy NL-

Result Comparision

Material	Equivalent Stress (MPa)		Equivalent Strain
	Min.	Max.	Min.	Max.
Copper Alloy NL	0.003649	328.62	7.335E-8	0.0030176
Aluminium Alloy NL	0.0024106	327.74	7.216E-8	0.0048122
Magnesium Ally NL	0.001539	248.61	7.439E-8	0.0055294

• From above table we can say that the max. stress induced in copper alloy and least is in magnesium alloy.
• Similarly max. strain induced in magnesium alloy and least in copper alloy.
• So we can say that copper alloy will not bend easliy and vice versa magnesium alloy we deform easliy so bending is easy in it.

Animated result-

1. Copper Alloy NL-

Equivalent stress-

2. Equivalent Elastic Strain-

Aluminium Alloy NL-

1. Equivalent Stress-

2. Equivalent Elastic Strain-

Magnesium Alloy NL-

1. Equivalent Stress-

2. Equivalent Elastic Stress-

Conclusion-

• A concise finite element model for simple wire strand subjected to pure bending has been established. Precise analytical boundary condition has been developed.
• From results we can conclude that the copper is most elastic material and magnesium is least one.

• Characteristics we can enhance or decrease include:

  • Strength
  • Abrasion resistance
  • Corrosion resistance
  • Crushing resistance
  • Fatigue resistance
  • Rotation resistance. Flexibility