Week 4 -Wire Bending Challenge

Procedure:

• Drop Static Structural
• Open the Engineering data and choose Copper NL, Alluminium NL and Magnesium NL as material.
• Right click on geometry and import the model.
• Open mechanical model
• Rename the geometry as Wheel, Wire and Lever
• Click on the wire and assign the concerned material.
• Click on the connections and expand the contact.
• Delete the contacts - 1. wheel and wire & 2. Lever and wheel.
• we are left with Lever and Wire.
• Duplicate this contact and then flip it.
• Select Rename based on the definition.
• Select the 2nd contact and select the outer surface of the wheel as contact and
• Target is wire

Select both the Contacts -

• Type - Frictional
• Frictional Coefficient - 0.2
• Formulation - Augmented Lagrange
• Normal Stiffness - Factor
• Normal Stiffness Factor - 0.1
• Update Stiffness - Each Iteration
• Interface Treatment - Add Offset, Ramped effects

Meshing -

• Right click on Mesh and Insert method.
• Select the three bodies and apply in Geometry
• Select the method as Automatic
• Let general mesh be of size 8mm

Analysis Settings:

• Numer of steps should be 8
• For Step 1 -

For Step 2-8

• 

Output Controls should be Yes

• Apply the Revolute Joint on the body of Lever.
• and Change its coordinate for Zand X axis

Load:

• Insert the fixed support for wheel
• Insert the rotation joint
• 

Provide the output Controls.

Objective: To perform an analysis to simulate the bending of a wire in ANSYS and to find out the Equivalent stress and Equivalent strain on the wire alone. Use Copper Alloy (Non Linear), Aluminium Alloy (Non-Linear), and Magnesium Alloy (Non-Linear) for the wire alone.

Case 1: Copper NL

Equivalent Stress:

Equivalent Strain:

CASE 2 : Alluminium NL

Equivalent Stress -

Equivalent Strain -

CASE 3 : Magnesium Alloy NL

Equivalent Stress:

Equivalent Strain :

RESULT:

S.No	Material	Stress (MPa)	Strain(mm/mm)
1.	Copper NL	329.92	0.0031441
2.	Alluminium NL	298.8	0.0042116
3.	Mgnesium NL	254.1	0.0058155

CONCLUSION:

• Copper NL has the highest stress whereas Magnesium has the lowest stress.
• Magnesium has the highest equivalent strain whereas Copper has the lowest equivalent Strain.