Week 4 -Wire Bending Challenge

Aim:

To perform an analysis to simulate the bending of a wire in ANSYS by using Copper Alloy (Non Linear), Aluminium Alloy (Non-Linear), and Magnesium Alloy (Non-Linear) for the wire alone. And find out the Equivalent stress and Equivalent strain on the wire alone. Compare the results and submit a well-formatted report on this.

Procedure:

First we have to start the ansys workbench, double click on static structural analysis and rename it wire bending.

Now double click on engineering data to edit and add all the required material for this simulation.

All the three material required for the simulation and in addition to this structural steel is their by defaut.

Next right click on geometry and click on upload the geometry.

And then again double click on geometry to edit in spaceclaim geometry looks good as shown below.

After closing spaceclaime right click on model and click on update.then double click on model na mechanical windows open.

After that click on geometry and rename it as shown below.

Then assign copper alloy NL to wire as material.

then click on coordinate and create a coordinate at the location shown below.

After that right click on contact and insert two manual contact one is lever and wire and another is wire andwheel of frictional type with coeffiecien of friction 0.2,

one more revolute joint is added to it to the hole of lever and also change the coordinate as shown below.

After that we right click the mesh and insert the method and select the all body and change the type to tetra hedron,then again right click to the mesh and insert the sizing and select all the contact faces with wire and give the element size as 2.2mm.And lastly right click on mesh and select the sizing and make the type as spherical influenced,sphere centre as coordinate system that we have created and give the sphere radius as 7mm and element size as 0.8 mm

after that click on analysis setting and change the step to 8 and for the first step options are shown below.

And for the 2nd to 8th step the option changed are show below.

After that we have to gibe boundry condition so first i gave the fixed support to the wheel hole and the top face of the wire,abd second we have to add joint load type as rotation and magnitude as tabular data as shown below.

And in the solution part we have to add the equivalent stress and equivalent strain for the wire alone.

After that right click on solution and click solve.

Results:

Equivalent strain generated in wire alone :

Max value of strain is 0.0031761

Equivalent stress generated in wire alone:

Max value of stress is346.44 Mpa.

Case 2: wire material as Alluminium Alloy NL.

Procedure is same as it is only need to change the material of wire to Alluminium Alloy NL.

we had changes in contacts also for the friction contact between wheel and whire added some faces to in contact.

also some changes in contact setting like stifness factor.

We had some changes in mesh as the previous setting is not working for this case the changed mesh is shown below.

Some changes in analysis setting like the time steps and stablization as shown below.

this is for the first step.

this mage is for the 2nd to 8th

Results:

Equivalent strain generated in wire alone :

Max value of strain is 0.0060448

Equivalent stress generated in wire alone:

Max value of stress is 427.07 Mpa.

Case 3: wire material as Magnesium Alloy NL.

Procedure is same as in case 2 it is only need to change the material of wire to Magnesium Alloy NL.

Results:

Equivalent strain generated in wire alone :

Max value of strain is0.010143

Equivalent stress generated in wire alone:

Max value of stress is452.55 Mpa

Discussion:

Material used	Equivalent strain on wire alone	Equivalent stress on wire alone (Mpa)
Copper Alloy NL	0.0031761	346.44
Aluminum Alloy NL	0.0060448	427.07
Magnesium Alloy NL	0.010143	452.55

Conclusion:

After seeing all the rsults we concluded that in bending magnesium alloy wire the stress is generated high and the copper alloy wire bend easly because the stress is generated less among all.

as well the computation time also increased after chnaging the material.