Week 4 -Wire Bending Challenge

Objective: To compare the equivalent stress and strain on the wire made of 3 different materials. The materials used are Copper Alloy(Non Linear), Aluminium Alloy(Non Linear) and Magnesium Alloy(Non Linear).

Materials:

	Youngs Modulus	Poisson Ratio	Yield Strength	Target Modulus
Copper Alloy NL	11000	0.35	280	1150
Aluminium Alloy NL	72000	0.33	280	500
Magnesium Alloy NL	45000	0.34	193	920

Model: (Common for all 3 cases)

It consists of 3 Parts: Whee, wire and Lever.

Connections:(common for all 3 cases)

1. Contacts sets:

All the contact sets are frictional with a frictional coefficient of 0.2.

A contact set is established between the lever and the wire.

Another contact set is established between wheel and wire.

2. Revolute joint: A revolute joint is set up between the ground and lever. Rotation os along the Z-axis.

Mesh: The meshing is done in 3 steps in order to get fine mesh.

1. Method- Tetrahedrons. it is applied to all 3 bodies to get tetrahedrons structure.

2. Sizing- 2.2mm. The outer face of the lever which is contact with the wire is more refined to better results.

3. Sizing- Sphere of radius 7mm . A sphere is created around the region where the wire bends when rotated by the lever. This is done to get accurate values.

Nodes - 8129:

Elements - 4082:

Analysis Settings:

it is divided into 8 steps. Large deflection is turned on along with the output controls.

1. Fixed Support: Wheel is fixed.

2.Fixed Support 2: The wire beginning is fixed to prevent slipping.

Results:

1. Equivalent Stress:

a. Copper Alloy NL

b. Aluminium Alloy NL

c. Magnesium Alloy NL

2. Equivalent Strain

a. Copper Alloy NL

b. Aluminium Alloy NL

c. Magnesium Alloy NL

Max values	Equivalent Stress(MPa)	Equivalent Strain
Copper Alloy NL	336.46	0.003088
Aluminium ALloy NL	340.22	0.0048335
Magnesium Alloy NL	246.71	0.0014989