Week 4 -Wire Bending Challenge

Wire Bending Challenge

AIM :For this challenge, you will have 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), and Magnesium Alloy (Non-Linear) for the wire alone. You need to find out the Equivalent stress and Equivalent strain on the wire alone. Compare the results and submit a well-formatted report on this.

Process:

• Download the model and import into ansys geometry
• Add the materials for the wire Engineering Data i.e;
• Copper Alloy (Non Linear)

• Aluminium Alloy (Non-Linear)

• Magnesium Alloy (Non-Linear)

• Open the geometry and check any defects if any

• Update the model and open it
• In geometry keep the rename as they are

• Connections are made between Wheel Wire & Wire-Lever

• In mesh insert methord for tetra mesh

• For face sizing Select wire as we want a good mesh to get better analysis
• Use coordinate near wire-wheel contact as we need to analysis that region more because that region more non-linear bending occurs

• Follow the analysis setting as given

• Fix wire face & Wheel

• Rotate lever in z-axis as required

• In solution insert Equivalent stress and Equivalent strain on the wire alone as given

Equivalent stress

Equivalent strain

Aluminium Alloy (Non-Linear) & Magnesium Alloy (Non-Linear)

For the other 2 materials duplicate and rename

Open workbench-model and in geometry select wire

Change material to Aluminium

For other case select as Magnesium Alloy (Non-Linear)

Clear the solution data and rerun Solve

FOR

Aluminium Alloy (Non-Linear)

Equivalent stress

Equivalent strain

Magnesium Alloy (Non-Linear)

Equivalent stress

Equivalent strain

Compare the results

	Equivalent stress	Equivalent strain
Copper Alloy (Non Linear)	647.4MPa	0.0059167
Aluminium Alloy (Non-Linear)	442.7MPa	0.0062768
Magnesium Alloy (Non-Linear)	473.66MPa	0.01058

We can observe that

• The Equivalent stress of Aluminium Alloy (Non-Linear) is low when compared two Magnesium Alloy (Non-Linear) & Copper Alloy (Non Linear)
• The Equivalent strain of Copper Alloy (Non Linear) is low when compared other two Aluminium Alloy (Non-Linear) & Magnesium Alloy (Non-Linear)

Thus from observation we can say that If you are going for safety go with Aluminium Alloy (Non-Linear) as it has Equivalent stress of 442.7MPa which is low as compared to two other materials

If you are going with economy go with Magnesium Alloy (Non-Linear) as its safety & Equivalent strain is in better position as compared to two other materials