Week 4 -Wire Bending Challenge

Aim - To simulate the bending of a wire in ANSYS. We have to use Copper Alloy (Non Linear), Aluminium Alloy (Non-Linear), and Magnesium Alloy (Non-Linear) for the wire alone. We need to find out the Equivalent stress and Equivalent strain on the wire alone compare and draw conclusions.

Procedure -

1. First we will import the model and give three material from engineering data Copper Alloy (Non Linear), Aluminium Alloy (Non-Linear), and Magnesium Alloy (Non-Linear)

2. Rename the components and assign material to material to wire as required for simulation.

3. wire wheel, lever and wheel contact should be deleted.

4. contacts are to be flipped for the remaining and wheel and wire contact is to be given with target as wire.

5 Frictional contact to be given with 0.2 coeff of friction, formulation to be argumented lagrange and normal stiffness be by factor of 0.1.

6. Tetrahedrons mesh is to be given to all components. Face sizing of 2.2 is to given to wire Curved face.

7. We will create a spherical cordinate system and translate it near wire and we will give element size as 0.8 around that co ordinate system.

8. Then we will give proper analysis system settings.

9. Then we will create proper revolute joint with correct orientation of the axis.

10. Now we will give proper rotational values and fixed support as required.

11. Now we will give the output results as we want and start solving it.

Result and conclusion:

Deformation that is suppose to happen should be same so we cannot compare material on that basis but looking at max stress values, Magnesium Alloy NL performs far better as compared to others.

Simulation file links

: https://drive.google.com/drive/folders/1xQ4pokenquB4DA09nWHRB66QaszMJxKo?usp=share_link