Week 4 -Wire Bending Challenge

Objective:

To simulate the bending of a wire with Copper Alloy (Non-Linear), Aluminium Alloy (Non-Linear) and Magnesium Alloy (Non-Linear) as Wire Material as well as Compare and study result plot like Equivalent Stress and Strain for Wire.

1. Analysis System: Static Structural
2. Material Properties:

• Wire – Copper Alloy NL / Aluminium Alloy NL / Magnesium Alloy NL
• Wheel – Structural Steel
• Lever – Structural Steel

• Aluminium NL

• Coppper NL

• Magnesium NL

3. Mesh: 
   • Patch Conforming Method – Tetrahedrons
   • Face Sizing – 2.2 mm on four faces

• Face Sizing of 0.8 mm using Sphere of Influence of 7 mm on Face of wire

4. Joints

Revolute Joint is given on Inner cylindrical face of Lever

5. Analysis Setting

No of Steps: 8

Large Deformation: ON

Solver Type: Direct

6. Fixed Support

• Fixed Support on Wheel

• Fixed Support on end face of wire

7. Joint Load

Rotational Joint load of 140 degree is given on Lever in total 8 steps as 0,20,40,60,80,100,120,140,140.

 

Result Plot:

1. Aluminium Wire

Equivalent Stress
Equivalent Strain

 

2. Copper Wire

Equivalent Stress
Equivalent Strain

 

3. Magnesium Wire

Equivalent Stress
Equivalent Strain

 

 

Conclusion:

Material	Aluminium Wire	Copper Wire	Magnesium Wire
Equivalent Stress	339.35	330.02	266.62
Equivalent Strain	0.0048219	0.0030401	0.0059409

 

1. From above result table, it is clear that Aluminium Wire has maximum equivalent stress equal to 339.35 Mpa.
2. And Copper Wire has minimum equivalent strain equal to 0.0030401.