Week 4 -Wire Bending Challenge

Objective: In this study simulation of wire bending has done. This study compares the results at different cases.

In this study, I have performed an analysis to simulate the bending of a wire in ANSYS.I use Copper Alloy (Non-Linear), Aluminium Alloy (Non-Linear), and Magnesium Alloy (Non-Linear) for the wire alone. I find Equivalent stress and Equivalent strain on the wire alone and compare the results. This study is done in Ansys 2022

Procedure:

1.Geometry

• Input the model as Step format in geometry

2.Material assignment

• Open Engineering Materials and select the required material.
• I add the material in ANSYS for wire Copper Alloy (Non-Linear), Aluminium Alloy (Non-Linear), and Magnesium Alloy (Non-Linear), but initially study is starting with copper alloy (NL).

3.Meshing

• For Meshing the body select the three bodies and give the tetrahedron mesh method

• Give face size =2.2mm

• Give element size by sphere radius influence by creating additional coordination system

Meshed bodies

4.Boundary condition

Connection

1.Contact creation

(a)

• Select the faces of wire as contact and lever as Target
• Definition > type - Frictional
• Advanced > Formulation - Augmented Langrage
• Geometric Modification > Interface Treatment - Add offset Ramped effect

(b)

• Select the faces of wheel as contact and Wire as Target
• Definition > type - Frictional
• Advanced > Formulation - Augmented Langrage
• Geometric Modification > Interface Treatment - Add offset Ramped effect

2.Analysis Setting

• Create the analysis setting for first load step

• Create the analysis setting from second load step to Eighth load step

3. (a) Fixed support the wire face (Insert by right click on analysis setting)

3. (b) Fixed support2 the Wheel(Insert by right click on analysis setting)

3. (c) Displacement restriction of wire in Y direction (Insert by right click on analysis setting)

3. (d) Joint rotation (Insert by right click on analysis setting)

Results (output):

Stress

Max stress= 340.69Mpa

Stress in wire

Max stress= 340.69Mpa

Strain

Max Strain =0.0031133 mm/mm

Now compare these results for different material condition by parametric study by selecting the P symbol as above results which will required for comparing

(Case1 and case 2 result out put)

Case 3 result output

• Select the Aluminum alloy (Nonlinear) for Wire
• I found that result for prior above condition is not converged in this material condition from load step 2 so I change the analysis setting from load step 2 to load step 8. I reduced the Minimum time limit size from 0.01 to 0.001 .

Max stress= 343.91Mpa

Strain

Max Strain =0.004878m/mm

Whole setup animation

Conclusion:

By comparing the result, the study shows that with selecting material of copper alloy (NL) shows the less strain value generation compare to other material selection. So, it is best to use because of high value of young modulus, it means More capability of elongation or ductile nature during bending.