Week 4 -Wire Bending Challenge

Objective:- In this challenge objective is to perform wire bending operation by assigining it a material of nonlinear copperalloy,aluminium alloy and Magnisium alloy. And results are analysed for the strain and stress generation within wire during bending and critical regions are identified.

Set-up - and preprocessing for the simulation to carry out in ANSYS are as follows:-

After importing the parasolid geometry into the geometry module Editing need to be done in space claim.After that the desired material was selected from the engineering material resourse,As specified in the challenge There are three materials to be used for wire one by one (non linear copper alloy,alluminium alloyand magnisium alloy).

Then the geomerty was updated into the mechanical model, here first material was assigned ,then contact region was created ther is contact of two piars has to define ,first the contact between the wire and bending hub and second the contact between the wire and the holding die (wheel).

Revolute joint is created at the centering hole in the bending plate,

Then meshing configuration Ar as follows ,

the elements are tetrahedrals, and

the sphere of influence was created with 0.7 mm mesh ascrodd the bending region.

element size: 0.7 mm

face sizing for wire: element size :- 2.2 mm

element size:

Nodes: 4982

element: 2517

Analysis setting are craeted with 8 itteration first one having a different configuration and fron 2-8 having other connfiguration.

fixed support is given to wheel and the rotation is applied gradually to the lever .

In this way all the pre-processing had done and the results we are intrested in the stres generation on the wire and strain generation on wire for each case.

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Case 1 Material used copper alloy non linear:-

Equivalent strain

Equivalent stress

strain in the wire

stress in the wire

Case 2) Material used Aluminium alloy non linear:-

Equivalent strain

Equivalent stress

strain in the wire

stress generation in wire

Case:3) Material used Magnesium alloy non linear:-

strain in the wire

Equivalent stress

stress generation in wire

Equivalent strain

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comparisions of results:-

MATERIAL	ALLUMINIUM ALLOY	COPPER ALLOY	MAGNESIOUM ALLOY
Total Deformation max Min	262.64 0	677.84 0.00033643	262.64 0
Equivalent stress max Min	321.59 0.0025908	677.84 0.00033643	264.4 0.0017379
Equivalent strain max Min	0.0066136 4.9964e-9	0.0061929 5.4912e-9	0.011025 3.502e-9
Equivalent stress for max wire min	467.78 0.00011067	363.78 0.0048824	494.88 5.653e-5
Equivalent strain for max Wire min	0.0066155 3.2208e-9	0.0061992 3.774e-9	0.011034 6.1425e-9

So, the results are listed above As we see the stress generation in the copper case is high Also the contact pressure is also highest,It means that the copper elasticity graph is more stiffer than the other two material used. The aluminium is providing less resistance to bending strain thats why the stress generation in this case is lower than the copper alloy case.

for magnisium case it is again lower,than the upper two cases so it is providing the high stifness behaviour but by entering into the plastic region the strain generation is very low.

Thus in all cases the plastic region of the the wire has reached upto its extreme limit, and that causing a bending phenomenon.