Week 4 -Wire Bending Challenge

Case Study of Wire Bending Mechanism.

Objective:

for this challenge, you will have to perform an analysis to simulate the bending of a wire in ANSYS. You will have to use Copper Alloy (Non Linear), Aluminium Alloy (Non-Linear), and Magnesium Alloy (Non-Linear) for the wire alone. You need to find out the Equivalent stress and Equivalent strain on the wire alone. Compare the results and submit a well-formatted report on this.

Procedure:

Case1:

For Case 1, Static Structural Analysis is carried out on Wire Bending Mechanism. The material is Copper Alloy NL and the analysis is carried out on Ansys Workbench. The geometry of the model is imported on the Ansys Workbench for analysis.

2D Geometry is extruded in the Space Claim to get the model to be imported to the ANSYS. The Extruded model is as shown in the image below:

The properties of the material is stated below:

Density

8.3e-06 kg/mm³

Structural

Young's Modulus	1.1e+05 MPa
Poisson's Ratio	0.34
Bulk Modulus	1.1458e+05 MPa
Shear Modulus	41045 MPa

The model is meshed using Ansys Mesher with an element size of 2.2 mm, and a patch conforming method using tetrahedrons was employed. This is done to get the best refinement within the limitation of Ansys Academic License.

A mesh metric that identifies the elements according to their quality was employed and it can be seen that element of lowest quality are minimal. Most of the elements have very high quality in the range of 0.7-1. Hence, the mesh is of acceptable quality. The meshed model is shown in image below:

The simulation is then run with the setting and the results are then obtained.

Case 2:

The material of the wire is Aluminum Alloy NL and the properties of the material is stated below:

Density 2.77e-06 kg/mm³ Structural Young's Modulus 71000 MPa Poisson's Ratio 0.33 Bulk Modulus 69608 MPa Shear Modulus 26692 MPa

Case 3:

The material of the wire is Magnesium Alloy NL and the properties of the material is stated below:

Density

1.8e-06 kg/mm³

Structural

Young's Modulus	45000 MPa
Poisson's Ratio	0.35
Bulk Modulus	50000 MPa
Shear Modulus	16667 MPa

Results:

Equivalent Stress of the 3 cases are compared.

Time [s] Minimum [Mpa] Maximum [Mpa] Average [Mpa]

8. 3.6798e-003 351.63 73.6
9. 2.3486e-003 326.63 60.30
10. 1.3679e-003 251.02 52.34

Equivalent Elastic Strain of the 3 cases are compared.

Time [s] Minimum [Mpa] Maximum [Mpa] Average [Mpa]

8. 2.2645e-008 3.2273e-003 8.2756e-004
9. 1.9976e-008 4.7378e-003 1.0792e-003
10. 1.1913e-008 5.5961e-003 1.4091e-003

The Equivalent stress is plotted on the plate and is as shown below

The Equivalent Elastic Strain is plotted on the plate and is as shown below

Conclusion:

Analysis for all the three material is carried out and it comes to the conclusion that, average minimum stress in case of Magnesium alloy NL is 52.34 Mpa which is less than that of Copper alloy NL (i.e 73.6 Mpa) and Average Equivalent Elastic strain for Magnesium Alloy NL is 1.4091e-003 Mpa which is more than that of Copper alloy NL 8.2756e-004.