Week 4 -Wire Bending Challenge

Aim:

To perform an analysis to simulate the bending of a wire in ANSYS. You will have to use

Copper Alloy (Non Linear),

Aluminium Alloy (Non-Linear),

Magnesium Alloy (Non-Linear)

for the wire alone.

Case_2:

Objective :

You need to find out the Equivalent stress and Equivalent strain on the wire alone. Compare the results

procedure for the Wire Bending for static structural analysis :

1) material selection : Copper

2) Geometry: Import from the folder

3) model : Edit

model itself will edit and simulate the parameter

Static structural:

selection of the step as follows

1. Material selection
2. Geometry
3. Model
4. Setup
5. Solution
6. Result

selection of the step as follows

1. Geometry : Rename the component as per requirement

1. Material : Assign the material as per requirement here is Copper

Coordinate system:

Create new coordinate system for the wire

as per the offset x and z axis for it should be on wire

x offset =3mm

y offset= -3mm

Connection :

• Contact
• joints

• Contact :

1) frictional: wire to lever

2) frictional :wheel to wire

• joints : Revolute : ground to lever

mesh :

1. method
2. face size
3. face size 2

method:

geometry : 3 bodies

type: tehtrahedrons

face size : contacted region for the analysis

geometry : 4 faces

element size: 2.2mm

face size : for wire

element size: 0.8mm

geometry : 1 faces

sphere of radius : 7mm

now generate the mesh :

Inpute for the static structural :

1.Analysis setting

2. Fixed support

3. Fixed support

4. joint - rotation

1)Analysis setting :

number step	8
Auto timing step	on
Defined	time
Initial time	0.1s
minimum time	1e-2s
maximum time step	0.2s
Solver type	Direct
LArge deflection	on

Fixed support : for wheel

Fixed support 2: for wire

joint - rotation:

joint	ground to lever
DOF	rotation z
Type	rotation
Magnitude	tabular data

Magnitude :

Sr.no	Time	Rotation
1	1	-20
2	2	-40
3	3	-60
4	4	-80
5	5	-100
6	6	-120
7	7	-140
8	8	-140

Solution we need to take :

Equivalent stress:

Total deformation :

Equivalent Elastic strain

Equivalent Elastic strain 2

Equivalent stress 2:

Contact tool: (Pressure)

Force reaction

Force reaction 2

now click on the solve bottom

Here the result for the copper wire case images :

Equivalent stress:

Total deformation :

Equivalent Elastic strain

Equivalent Elastic strain 2

Equivalent stress 2:

Contact tool: (Pressure)

Force reaction

Force reaction 2

Compare the three material result for the wire simulaton as bellow :

Sr. no	Cooper	Alluminium	Magnesium
Equivalent stress	346.44MPa	333.84MPa	249.95MPa
Equivalent strain	8.4701e-004	9.0779e-004	9.926e-004
Total deformation	262.64mm	262.64mm	262.64mm

Conclusion :

Copper wire has the highest Equivalent stress 346.44MPa

and minimum Equivalent strain - 8.4701e-004

I have attached the wire file with this report for the further reports