Week 4 -Wire Bending Challenge

Aim : perform an analysis to simulate the bending of a wire in ANSYS. use Copper Alloy (Non Linear), Aluminium Alloy (Non-Linear), and Magnesium Alloy (Non-Linear) for the wire alone

Procedure:

OPen ANSYS workbench and open static strictural module.

open engineering data and select material like stuctural steel, Copper alloy NL, Aluminum Alloy NL, And magnesium alloy NL.

The mechanical property of stuctural steel is as given below

Mechanical property of aluminum alloy NL is as given below

Mechanical property of copper alloy NL is as given below

The mechanical property of Magnesium Alloy NL is as given below

NOw close the engineering data and upload geometry in spacecliam . and open spaceclaim using edit option , we check geometry as we found all good to proceed we close the spaceclaim and update model, and open mechanical model

now expand the geometry and rename the component for better conveninet

and apply copper alloy NL to wire and rest two component structural steel material

for contact :

1. frictionaless contact between wheel and wire as shown as below

2. frictionless contact between wire and roller

3. deploy a revolute joint to the roller as shown below

connection Type : body to ground
Type: revolute

for mesh : we use tetrahedron mesh using patch conforming algorithm
wheel and roller with element size as 4 mm/

contact surface between wire , roller and wheel , element size will be 2.2 mm
and wire mesh will be mesh with influence of sphere with the radius of 7 mm and element size as 0.8 mm

check mesh quality: mesh quality worksheet
error limit: agressive mechanical
target element quality : 5E-002
Smoothing : Low

The statics of mesh are gven below

The number of node : 32056
number of element : 19174

the element quality as given below

now for analysis setting we use 8 step
for step no 1
auto time steping : on
define by : time
initial time step: 0.1 s
min time step 0.01 s
max time step : 0.2 s
solver type : direct
weak spring : program controll
Large deflection : on
solver pivot checking : Program controll
for output controll

set all parameter as yes

for 2nd to ith step

auto time steping : on
define by : time
initial time step: 0.1 s
min time step 0.01 s
max time step : 1 s
solver type : direct
weak spring : program controll
Large deflection : on
solver pivot checking : Program controll
for output controll

set all parameter as yes

now deploy the fixed load to wheel as per given below

also deploye fixed load support to wire end to avoid slip as shown below

now deploy a rotation load to the lever with magnitude handle by tubular data , the details of tubular data is given below

NOw list out required uotput from simulation and run

Picture :

Total deformation

Equivalent elastic strain

Equivalent strain on wire

Equivalent stress

Equivalent stress on wire

'

COntact pressure

Frictional force reaction wheel to wire

Frictional force reaction wire to lever

Case 2:

WE change wire material as aluminum alloy NL

rest setting will be same as previous case only analysis setting time step will be change as belwo

for 1st step

Initial time step: 0.05 s

Min time step : 0.01 s
max time step : 0.5 s

For 2nd to 8th step
Min time step : 0.05 s
max time step : 0.5 s

Picture :

total deforamtion:

Equivalent elastic strain:

Equivalent strain on wire :

Equivalent stress

Equivalent stress on wire

COntact pressure

Frictional force reaction wheel to wire

Frictional force wire to lever

Case 3 : Wire material is magnesium alloy NL

rest all the setting will be same as case 2

Picture :

Total deformation

Equivalent strain

Equivalent strain on wire alone

Equivalent stress

Equivalent stress on wire

Contact pressure

Force reaction at wheel to wire

Force reaction at wire to lever

Result :

		Copper	Aluminium	Magnesium
Total deformation	Max	262.64 mm	262.64 mm	262.64 mm
	Min	0. mm	0 mm	0. mm
Total elastic strain	Max	2.95E-03	4.54E-03	5.85E-03
	Min	3.18E-09	3.18E-09	3.22E-09
Equivalent strain on wire	Max	2.95E-03	4.54E-03	5.85E-03
	Min	6.58E-08	6.70E-08	6.89E-08
Equivalent stress	Max	323.53 MPa	321.35 MPa	262.38 MPa
	Min	4.8001e-004 MPa	4.156e-004 MPa	4.4752e-004 MPa
Equivalent stress on wire	Max	323.53 MPa	321.35 MPa	262.38 MPa
	Min	4.0498e-003 MPa	2.6043e-003 MPa	1.6286e-003 MPa
Contact pressure	Max	456.93 MPa	207.77 MPa	258.03 MPa
	Min	0. MPa	0. MPa	0. MPa
Frictional force reacrion wheel to wire	Total	660.22 N	423.65 N	359.04 N
Frictional force reaction wire to lever	Total	541.21 N	376.95 N	299.68 N

Conclution :

1. Magnesium alloy NL material experiance least stress comprared to all material which is 262.38 MPa, rest two material experiance near about same stress which is 323.53 MPa for copper alloy NL and 321.35 MPa for aluminum alloy NL

2. simillarly Magnesium alloy material feels max strain which is 0.005846 and aluminium alloy have von misses strain of 0.0045417 and least to copper which is 0.0029452