Week 4 -Wire Bending Challenge
AIM:
Perform Advanced Static Structural Analysis to Simulate the Wire dending operation in ANSYS WORKBENCH. We are going use three similar materials i.e Copper Alloy (Non Linear), Aluminium Alloy (Non Linear) and Magnesium Alloy ( Non Linear) for the wire alone.
GIVEN MODEL:
*Three Main Parts Wire bending operation that is :
1.Lever.
2.Wheel.
3.Wire.
PROCEDURE:
Assign the material as structural steel for both the cases by, Selecting the Engineering data >> Edit >> Engineering data sources >> General Materials >> Structural steel.
*Properties of the structural steel is shown in below.
*Assign the Structurl steel for both the wheel and the Lever.
STRUCTURAL STEEL:
*After Assigning the material close the engineering data and open new space claim to make the required designs.
*Once geometry is imported from the space claim then open the model and eidt the geometry in Mechanical moduler.
*Assign the Contacts and targets according to the design model with contact type is Frictional, behavour is Program Controlled, Augmente Lagrange Formulation.
*Wire is Contact and traget is lever.
**Wheel is Contact and traget is wire.
*Create one revolute joints and two fixed joint and then assign joint loads.
*After that Give all analysis settings in steps of time.
Settings for Step-1 Settings for Step-2 to 8
CASE-1
COPPER ALLOY NL:
EQUIVALENT VON-MISES STRESS:
MAX: 647.41 (Mpa) and MIN:8.530E-5 (Mpa)
EQUIVALENT ELASTIC STRAIN:
MAX:0.0059478 and MIN:1.25E-9
ALLUMINIUM ALLOY NL:
EQUIVALENT VON-MISES STRESS:
MAX: 451.76(Mpa) and MIN9.7066E-5 (Mpa)
EQUIVALENT ELASTIC STRAIN:
MAX:0.0064122 and MIN:2.1452E-9
MAGNESIUM ALLOY NL:
EQUIVALENT VON-MISES STRESS:
MAX: 478.15(Mpa) and MIN: 5.5811E-5 (Mpa)
EQUIVALENT ELASTIC STRAIN:
MAX:0.010647 and MIN:2.8703E-9
COMPARING THE RESULTS:
| SL.NO | MATERIAL | EQUIVALENT VON-MISES STRESS (Max) | EQUIVALENT VON-MISES STRESS(Min) | EQUIVALENT ELASTIC STRAIN (Max) | EQUIVALENT ELASTIC STRAIN(Min) |
| 1. | Copper Alloy | 647 | 8.5304E-5 | 0.005947 | 1.25E-9 |
| 2. | Alluminium Alloy | 451.76 | 9.7066E-5 | 0.0064122 | 2.1452E-9 |
| 3. | Magnesium Alloy | 478.15 | 5.5811E-5 | 0.010647 | 2.87403E-9 |
CONCLUSION:
*Magnesium material is preferable than copper Alloy and Alluminium Alloy because it required less strength to make wire bend and produce more strain than another two materials.