Week 4 -Wire Bending Challenge

Wire Bending Challenge Report

Aim: 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:

• Select Static Structural, drag and drop into Project Schematic.
• Choose material of as Copper Alloy NL, Magnesium Alloy NL and Aluminium Alloy NL under Engineering Data.
• Under geometry tab, import the given Big wheel, wire and rotating die geometry, double-click to open Space Claim to register the model.
• Then in Mechanical Module, assign material to the wire according to the case. The other models can remain at structural steel.
  • Case 1: Copper Alloy NL
  • Case 2: Magnesium Alloy NL
  • Case 3: Aluminium Alloy NL
• Assign a frictional connection between Wire to Rotating Die with coefficient of friction = 0.2.
• Assign a frictional connection between Big wheel to Wire with coefficient of friction = 0.2.
• Add a revolute joint to the rotating die.
• The mesh size was set to default and the mesh method was set to Tetrahedrons.
• The faces of the parts coming in contact is given a face mesh sizing of 2.2e-3.
• A sphere of influence of radius 7e-3 and with element size 8e-4 with the other surface of wire. The coordinate system is set to the point where the wire starts to bend.
• Under static structural tab, we set the analysis to 8 steps with auto timestep on and defined by time.
• Fixed supports are given to rotating die and the tip of the wire to hold them in place.
• Joint load is given to the revolute joint with 20deg increments.
• Equivalent Strain and Equivalent Stress plots are requested from the solver as outputs.
• Run the simulation by clicking on “solve”.

Case 1: Copper Alloy NL Wire

Equivalent Stress:

Equivalent Strain:

Case 2: Magnesium Alloy NL Wire

Equivalent Stress:

Equivalent Strain:

Case 3: Aluminium Alloy NL Wire

Equivalent Stress:

Equivalent Strain:

Conclusion:

The following data were obtained from the above cases:

Case - Material of Wire	Equivalent Stress (N/mm2)	Equivalent Strain
Case 1 - Copper Alloy NL	323.7	0.0030244
Case 2 - Magnesium Alloy NL	331.23	0.0030533
Case 3 - Aluminium Alloy NL	321.01	0.004563

We can see the maximum stress was undergone by Magnesium Alloy NL wire and the maximum strain was undergone by Aluminium Alloy NL wire.