Week 4 -Wire Bending Challenge

STATIC STRUCTURAL ANALYSIS ON WIRE BENDING

Objective

To perform an simulation of bending of a wire in ANSYS Workbench with three different material cases for wire

Case 1: Copper Alloy NL

Case 2: Aluminium Alloy NL

Case 3: Magnesium Alloy NL

To find out the equivalent stress and equivalent strain on the wire in all three cases and compare them.

Material data

Figure. 1 shows the structural steel's properties in Ansys Workbench engineering data. It was used as the wire bending model's material input expect the wire.

Figure. 1 Structural steel Engineering data.

Figure. 2 shows the Copper Alloy NL's properties in Ansys Workbench engineering data. It was used as the wire material input in Case 1.

Figure. 2 Copper Alloy NL Engineering data.

Figure. 3 shows the Aluminium Alloy NL's properties in Ansys Workbench engineering data. It was used as the wire material input in Case 2.

Figure. 3 Aluminium Alloy NL Engineering data.

Figure. 4 shows the Magnesium Alloy NL's properties in Ansys Workbench engineering data. It was used as the wire material input in Case 3.

Figure. 4 Magnesium Alloy NL Engineering data.

Model Geomentry

Figure. 5 shows the imported given Wire Bending model in the mechanical modular.

Figure. 5 Wire Bending model.

Connections

Initially the models are renamed as Wheel, Wire and Crank. Figure. 6 illustrates the contact and target faces of the Wire Bending model. In which the Wire is assigned as “Contact Bodies” and the Crank is assigned as “Target Bodies” and The conncetion is assigned as Frictional contact.

Figure. 6 Frictional-Wire to crank. 

Figure. 7 illustrates the contact and target faces of the Wire Bending model. In which the Wheel is assigned as “Contact Bodies” and the Wire is assigned as “Target Bodies” and The conncetion is assigned as Frictional contact.

Figure. 7 Frictional-Wheel to Wire.

Meshing

Tetragonal meshing han been done in it with a default meshing and the wire and crank contact face was face sized with a mesh element size of 1.2mm. In order to refine the bending area face meshing with type as Sphere of influence of 7mm radius and mesh element size of 0.4mm was assigned, as shown in Figure. 8. The over all mesh was shown in Figure. 9.

Figure. 8 Sphere of influence.

Figure. 9 Overall mesh of the model.

Fixed Joints

The Wheel is the stationary part in this model hence the inner face of the wheel was fixed and the face of wire inside the wheel is to be fixed to avoid sliping of the wire while bending. The two fixed supports are shown in Figure. 10 & Figure. 11.

Figure. 10 Wheel Fixed Joint.

Figure. 11 Whire Fixed Joint.

Rotational Joint

The crank is to be rotated to 140^o hence a rotational joint has been given to it since the  8 steps has been assigned in the analysis the rotation was increased by 20^o in each steps. The rotational joint is shown in Figure. 12.

Figure. 12 Crank Rotational Joint.

Simulation Results

Case1

Equivalent Elastic Strain

Figure. 13 illustrates the Equivalent Elastic Strain of Copper Alloy NL material with the wire and the rest of the bodies will be structural steel material. Since the maximum and minimum Equivalent Elastic Strain was not in the wire, the individual  maximum and minimum Equivalent Elastic Strain is shown in Figure. 14.

Figure. 13 Equivalent Elastic Strain of Wire Bending (Copper Alloy NL) with all bodies

Figure. 14 Equivalent Elastic Strain of Wire Bending (Copper Alloy NL)

Equivalent Stress

Figure. 15 illustrates the Equivalent Stress of Copper Alloy NL material with the wire and the rest of the bodies will be structural steel material. Since the maximum and minimum Equivalent Stress was not in the Wire, the individual  maximum and minimum Equivalent Stress is shown in Figure. 16.

Figure. 15 Equivalent Stress of Wire Bending (Copper Alloy NL) with all bodies

 

Figure. 16 Equivalent Stress of Wire Bending (Copper Alloy NL)

Total Deformation

Figure. 17 illustrates the Total Defprmation of Copper Alloy NL material with the wire and the rest of the bodies will be structural steel material. Since the maximum and minimum Total Deformation was not in the Wire, the individual  maximum and minimum Total Deformation is shown in Figure. 16.

Figure. 17 Total Deformation of Wire Bending (Copper Alloy NL) with all bodies

Figure. 18 Total Deformation  of Wire Bending (Copper Alloy NL)

Case 2

Equivalent Elastic Strain

Figure. 19 illustrates the Equivalent Elastic Strain of Aluminium Alloy NL material with the wire and the rest of the bodies will be structural steel material. Since the maximum and minimum Equivalent Elastic Strain was not in the wire, the individual  maximum and minimum Equivalent Elastic Strain is shown in Figure. 20.

Figure. 19 Equivalent Elastic Strain of Wire Bending (Aluminium Alloy NL) with all bodies

Figure. 20 Equivalent Elastic Strain of Wire Bending (Aluminium Alloy NL)

Equivalent Stress

Figure. 21 illustrates the Equivalent Stress of Aluminium Alloy NL material with the wire and the rest of the bodies will be structural steel material. Since the maximum and minimum Equivalent Stress was not in the Wire, the individual  maximum and minimum Equivalent Stress is shown in Figure. 22.

Figure. 21 Equivalent Stress of Wire Bending (Aluminium Alloy NL) with all bodies

Figure. 22 Equivalent Stress of Wire Bending (Aluminium Alloy NL)

Total Deformation

Figure. 23 illustrates the Total Defprmation of Aluminium Alloy NL material with the wire and the rest of the bodies will be structural steel material. Since the maximum and minimum Total Deformation was not in the Wire, the individual  maximum and minimum Total Deformation is shown in Figure. 24.

Figure. 23 Total Deformation of Wire Bending (Aluminium Alloy NL) with all bodies

Figure. 24 Total Deformation of Wire Bending (Aluminium Alloy NL)

Case 3

Equivalent Elastic Strain

Figure. 25 illustrates the Equivalent Elastic Strain of Magnesium Alloy NL material with the wire and the rest of the bodies will be structural steel material. Since the maximum and minimum Equivalent Elastic Strain was not in the wire, the individual  maximum and minimum Equivalent Elastic Strain is shown in Figure. 26.

Figure. 25 Equivalent Elastic Strain of Wire Bending (Magnesium Alloy NL) with all bodies

Figure. 26 Equivalent Elastic Strain of Wire Bending (Magnesium Alloy NL)

Equivalent Stress

Figure. 27 illustrates the Equivalent Stress of Magnesium Alloy NL material with the wire and the rest of the bodies will be structural steel material. Since the maximum and minimum Equivalent Stress was not in the Wire, the individual  maximum and minimum Equivalent Stress is shown in Figure. 28.

Figure. 27 Equivalent Stress of Wire Bending (Magnesium Alloy NL) with all bodies

Figure. 28 Equivalent Stress of Wire Bending (Magnesium Alloy NL)

Total Deformation

Figure. 29 illustrates the Total Defprmation of Magnesium Alloy NL material with the wire and the rest of the bodies will be structural steel material. Since the maximum and minimum Total Deformation was not in the Wire, the individual  maximum and minimum Total Deformation is shown in Figure. 30.

Figure. 29 Total Deformation of Wire Bending (Magnesium Alloy NL) with all bodies

Figure. 30 Total Deformation of Wire Bending (Magnesium Alloy NL)

Comparison Of Case 1, Case 2 & Case 3

Wire Materials	Parameters	Maximum	Minimum
Copper Alloy NL	Total Deformation	230.55 mm	0 mm
	Equivalent Stress	333.14 Mpa	0.00170 Mpa
	Equivalent Elastic Strain	0.00304 mm	1.8841e-8 mm
Aluminium Alloy NL	Total Deformation	230.61 mm	0 mm
	Equivalent Stress	313.36 Mpa	0.00106 Mpa
	Equivalent Elastic Strain	0.00441 mm	2.0083e-8 mm
Magnesium Alloy NL	Total Deformation	230.48 mm	0 mm
	Equivalent Stress	265.36 MPa	0.0007 MPa
	Equivalent Elastic Strain	0.00607 mm	2.0455e-8 mm

 

Conclusion

• From the above comparison the total deformation was same (approximately) in all cases but Equivalent Stress and Equivalent Elastic Strain differs.
• Case 3 attains the least Maximum Equivalent Stress and Case 1 attains the highest and similarly for Minimum Equivalent Stress also. This was direct opposite in Equivalent Elastic Strain.
• Thus, a structural analyses of the provided wire that was bent was done. For wires made of several non-linear alloys of the metals copper, aluminium, and magnesium, the required outputs of stress and strain generated on the wire were obtained and compared.