Challenge

Wire Bending

Aim:

To perform an analysis to simulate the bending of a wire in ANSYS-WORKBENCH.

Objective:

We will be using Copper Alloy (Non Linear), Aluminium Alloy (Non Linear) and Magnesium Alloy (Non Linear) for the wire alone and we need to find out the Equivalent stress and Equivalent strain on the wire alone and compare the results.

Procedure:

Initially we will providing a separate Co-ordinate System than the General Co-ordinate System in order to give a separate mesh where the contact of wire bending process will be happening to get better results.

Then we will proceed to give connections of contacts and joints of the case setup model.

First contact connections will be frictional between the wire surface and the lever surface as shown in the image below.

Then we will be providing contact connections which will be frictional between the wheel surface and the wire surface as shown in the image below.

Finally we will be giving joints in revolute from ground to lever for the rotation in tabular data with values in angles.

Now, we will be providing boundary conditions for the case setup model to make the process of wire bending happen.

Now we will be providing fixed supports in the surfaces mentioned in the images to arrest the movement in the model as shown in the two images below.

Then we will be providing joint rotation in angles where the revolute contact connections were given for the model.

Finally, we will be providing meshes with face sizing methods to get refined meshes at the point of contacts of the surfaces where it will be contacted. We will providing refined meshes on the wire and lever surfaces. And then we will be using the created Co-ordinate System to select it and provide sphere area of refined mesh for the area where the process of wire bending happens.

Simulation:

Case 1:

Equivalent Stress:

Time [s]

Minimum [MPa]

Maximum [MPa]

Average [MPa]

1

3.50E-02

8.55E-05

315.14

89.262

2

7.00E-02

5.42E-04

324.41

111.04

3

0.1225

6.18E-04

325.64

117.31

4

0.14088

8.61E-04

332.37

119.15

5

0.15925

9.23E-04

339.46

120.81

6

0.18681

9.48E-04

352.64

123.08

7

0.21437

1.32E-03

366.3

125.3

8

0.25572

1.50E-03

387.15

127.58

9

0.29706

2.19E-03

405.58

129.89

10

0.31877

2.22E-03

413.35

131.36

11

0.34047

2.58E-03

420.66

132.72

12

0.37303

2.82E-03

432.51

134.78

13

0.40559

2.99E-03

443.21

136.75

14

0.45443

3.25E-03

460.67

139.65

15

0.47152

3.63E-03

464.9

140.9

16

0.48861

3.79E-03

469

141.84

17

0.51425

3.95E-03

475.73

143.38

18

0.53989

3.96E-03

485.4

144.88

19

0.57835

4.34E-03

500.34

146.71

20

0.59854

4.54E-03

506.67

148.18

21

0.61873

4.75E-03

513.08

149.26

22

0.64902

5.07E-03

523.25

150.61

23

0.67931

5.11E-03

532.58

151.97

24

0.72474

5.38E-03

546.03

153.61

25

0.74859

5.38E-03

552.79

155.1

26

0.77244

5.43E-03

559.21

156.1

27

0.80822

5.62E-03

568.38

157.12

28

0.86188

6.29E-03

583.14

158.41

29

0.91554

1.17E-02

598.07

155.98

30

0.95777

7.15E-03

612.85

153.22

31

1

6.25E-03

637.9

159.27

32

1.0422

6.70E-03

642.59

159.17

33

1.0845

6.70E-03

644.95

157.79

34

1.1478

1.05E-02

647.15

158.59

35

1.2111

1.24E-02

649.02

158.58

36

1.3062

1.58E-02

645.85

157.81

37

1.4487

1.52E-02

649.1

157

38

1.5187

7.82E-03

650.16

154.99

39

1.5887

7.50E-03

650.38

155.86

40

1.6937

1.08E-02

646.87

154.8

41

1.7987

9.92E-03

648.4

154.58

42

1.9562

7.94E-03

597.92

149.58

43

2

8.10E-03

558.85

145.71

44

2.0438

6.63E-03

504.83

140.65

45

2.0877

7.19E-03

469.39

135.91

46

2.1534

8.32E-03

415.78

131.18

47

2.252

8.36E-03

388.16

126.67

48

2.3506

7.70E-03

377.97

123.87

49

2.4986

8.45E-03

351.23

120.06

50

2.5686

8.51E-03

350.17

118.42

51

2.6386

7.53E-03

351.41

117.89

52

2.7436

9.69E-03

352.31

117.14

53

2.8486

8.34E-03

353.33

116.53

54

2.9536

8.35E-03

353.33

116.59

55

3

7.65E-03

353.59

116.48

56

3.0464

8.10E-03

353.51

116.42

57

3.0929

8.55E-03

353.86

116.53

58

3.1625

8.40E-03

354

116.7

59

3.267

6.03E-03

351.87

117.2

60

3.3715

7.06E-03

354.18

117.96

61

3.5282

6.18E-03

349.39

119.23

62

3.685

4.74E-03

345.12

120.93

63

3.8417

5.43E-03

347.35

122.05

64

4

4.55E-03

343.92

123.04

65

4.1583

2.94E-03

342.28

124.3

66

4.3166

2.99E-03

342.15

125.75

67

4.3866

3.48E-03

340.09

125.88

68

4.4566

3.19E-03

338.56

126.7

69

4.5266

3.77E-03

335.22

127.82

70

4.6316

3.18E-03

329.91

129.08

71

4.7366

3.51E-03

328.87

129.97

72

4.8941

3.70E-03

340.54

131.53

73

5

3.58E-03

329.83

131.82

74

5.1059

2.42E-02

325.73

132.61

75

5.2118

1.84E-03

325.12

133.06

76

5.3706

4.79E-04

325.42

134.35

77

5.4406

7.92E-04

324.74

134.46

78

5.5106

5.29E-04

325.14

134.75

79

5.5806

2.44E-03

328.33

135.23

80

5.6331

4.04E-04

327.39

135.14

81

5.6593

5.72E-04

328.32

135.39

82

5.6856

4.63E-03

351.45

136.03

83

5.7118

8.88E-04

341.65

136.16

84

5.7381

9.75E-04

330.25

135.73

85

5.7643

4.98E-04

348.67

136.04

86

5.8037

1.03E-03

327.41

136.19

87

5.8628

2.64E-03

324.96

136.43

88

5.9218

5.23E-04

323.29

136.29

89

6

1.49E-03

350.85

137.05

90

6.0782

4.95E-04

336.95

137.13

91

6.1564

2.32E-03

324.79

137.16

92

6.2345

1.90E-03

326.2

137.53

93

6.3127

9.20E-03

326.97

137.98

94

6.43

2.96E-03

325.21

138.54

95

6.5473

4.42E-03

325.86

139.03

96

6.6646

6.48E-03

326.84

139.64

97

6.7818

3.34E-03

325.83

140.1

98

6.9577

6.39E-03

340.76

141.03

99

7

5.62E-03

332.05

141.05

100

7.0423

4.34E-03

331.7

141.04

101

7.0845

4.33E-03

331.65

141.03

102

7.1479

4.32E-03

331.63

141.02

103

7.243

4.31E-03

331.62

141.03

104

7.3856

4.31E-03

331.62

141.03

105

7.5856

4.31E-03

331.62

141.03

106

7.7856

4.31E-03

331.62

141.03

107

7.8928

4.31E-03

331.62

141.03

108

8

4.31E-03

331.62

141.03

Simulation Video - https://drive.google.com/file/d/1Ggb3Q5e1n0bR8GtFLrlwcwYy__AeIa38/view?usp=sharing

Equivalent Elastic Strain:

Time [s]

Minimum [mm/mm]

Maximum [mm/mm]

Average [mm/mm]

1

3.50E-02

1.26E-09

2.87E-03

8.46E-04

2

7.00E-02

5.65E-09

2.98E-03

1.09E-03

3

0.1225

9.76E-09

2.97E-03

1.16E-03

4

0.14088

8.73E-09

3.02E-03

1.19E-03

5

0.15925

1.38E-08

3.09E-03

1.20E-03

6

0.18681

1.73E-08

3.21E-03

1.23E-03

7

0.21437

2.11E-08

3.33E-03

1.25E-03

8

0.25572

2.77E-08

3.52E-03

1.28E-03

9

0.29706

3.39E-08

3.69E-03

1.30E-03

10

0.31877

3.58E-08

3.76E-03

1.32E-03

11

0.34047

3.92E-08

3.82E-03

1.33E-03

12

0.37303

4.37E-08

3.93E-03

1.35E-03

13

0.40559

4.81E-08

4.03E-03

1.37E-03

14

0.45443

5.52E-08

4.19E-03

1.40E-03

15

0.47152

5.70E-08

4.23E-03

1.41E-03

16

0.48861

5.94E-08

4.27E-03

1.42E-03

17

0.51425

6.25E-08

4.33E-03

1.44E-03

18

0.53989

6.64E-08

4.41E-03

1.45E-03

19

0.57835

7.11E-08

4.55E-03

1.47E-03

20

0.59854

7.34E-08

4.61E-03

1.49E-03

21

0.61873

7.58E-08

4.67E-03

1.50E-03

22

0.64902

7.95E-08

4.76E-03

1.51E-03

23

0.67931

8.32E-08

4.85E-03

1.53E-03

24

0.72474

8.34E-08

4.97E-03

1.54E-03

25

0.74859

8.36E-08

5.03E-03

1.56E-03

26

0.77244

9.29E-08

5.09E-03

1.57E-03

27

0.80822

9.60E-08

5.17E-03

1.58E-03

28

0.86188

9.38E-08

5.31E-03

1.59E-03

29

0.91554

1.44E-07

5.45E-03

1.57E-03

30

0.95777

9.88E-08

5.60E-03

1.55E-03

31

1

8.72E-08

5.86E-03

1.60E-03

32

1.0422

9.85E-08

5.90E-03

1.59E-03

33

1.0845

1.08E-07

5.91E-03

1.58E-03

34

1.1478

1.09E-07

5.93E-03

1.59E-03

35

1.2111

1.54E-07

5.95E-03

1.59E-03

36

1.3062

1.75E-07

5.92E-03

1.59E-03

37

1.4487

2.47E-07

5.95E-03

1.58E-03

38

1.5187

1.09E-07

5.96E-03

1.56E-03

39

1.5887

1.14E-07

5.96E-03

1.57E-03

40

1.6937

1.55E-07

5.94E-03

1.56E-03

41

1.7987

1.42E-07

5.96E-03

1.56E-03

42

1.9562

1.04E-07

5.50E-03

1.52E-03

43

2

1.13E-07

5.15E-03

1.48E-03

44

2.0438

1.32E-07

4.66E-03

1.44E-03

45

2.0877

1.25E-07

4.29E-03

1.39E-03

46

2.1534

9.38E-08

3.80E-03

1.35E-03

47

2.252

1.14E-07

3.55E-03

1.31E-03

48

2.3506

1.19E-07

3.46E-03

1.29E-03

49

2.4986

1.16E-07

3.23E-03

1.26E-03

50

2.5686

1.12E-07

3.19E-03

1.25E-03

51

2.6386

1.21E-07

3.20E-03

1.25E-03

52

2.7436

1.13E-07

3.21E-03

1.25E-03

53

2.8486

1.14E-07

3.22E-03

1.24E-03

54

2.9536

1.17E-07

3.22E-03

1.25E-03

55

3

1.18E-07

3.22E-03

1.25E-03

56

3.0464

1.16E-07

3.22E-03

1.25E-03

57

3.0929

1.17E-07

3.22E-03

1.25E-03

58

3.1625

1.23E-07

3.24E-03

1.26E-03

59

3.267

1.14E-07

3.20E-03

1.26E-03

60

3.3715

1.18E-07

3.23E-03

1.27E-03

61

3.5282

1.15E-07

3.18E-03

1.29E-03

62

3.685

1.03E-07

3.18E-03

1.31E-03

63

3.8417

1.09E-07

3.16E-03

1.33E-03

64

4

1.14E-07

3.13E-03

1.34E-03

65

4.1583

9.58E-08

3.12E-03

1.36E-03

66

4.3166

7.57E-08

3.12E-03

1.38E-03

67

4.3866

8.04E-08

3.10E-03

1.38E-03

68

4.4566

7.42E-08

3.08E-03

1.39E-03

69

4.5266

7.28E-08

3.05E-03

1.40E-03

70

4.6316

6.00E-08

3.01E-03

1.42E-03

71

4.7366

6.78E-08

3.00E-03

1.43E-03

72

4.8941

5.82E-08

3.12E-03

1.45E-03

73

5

4.06E-08

3.00E-03

1.45E-03

74

5.1059

2.47E-07

2.97E-03

1.46E-03

75

5.2118

2.83E-08

2.97E-03

1.47E-03

76

5.3706

8.54E-09

2.98E-03

1.49E-03

77

5.4406

1.62E-08

2.96E-03

1.49E-03

78

5.5106

9.14E-09

2.96E-03

1.49E-03

79

5.5806

2.68E-08

3.03E-03

1.50E-03

80

5.6331

8.65E-09

2.99E-03

1.50E-03

81

5.6593

7.61E-09

3.00E-03

1.50E-03

82

5.6856

4.40E-08

3.22E-03

1.51E-03

83

5.7118

1.06E-08

3.13E-03

1.51E-03

84

5.7381

1.21E-08

3.02E-03

1.51E-03

85

5.7643

9.92E-09

3.22E-03

1.51E-03

86

5.8037

1.18E-08

3.00E-03

1.52E-03

87

5.8628

5.66E-08

2.97E-03

1.52E-03

88

5.9218

6.51E-09

2.95E-03

1.52E-03

89

6

1.89E-08

3.22E-03

1.53E-03

90

6.0782

1.88E-08

3.11E-03

1.54E-03

91

6.1564

2.24E-08

2.96E-03

1.54E-03

92

6.2345

2.80E-08

2.98E-03

1.54E-03

93

6.3127

1.11E-07

3.00E-03

1.55E-03

94

6.43

4.25E-08

2.98E-03

1.56E-03

95

6.5473

7.93E-08

2.97E-03

1.57E-03

96

6.6646

1.15E-07

2.99E-03

1.58E-03

97

6.7818

7.34E-08

2.97E-03

1.59E-03

98

6.9577

1.20E-07

3.14E-03

1.60E-03

99

7

8.98E-08

3.05E-03

1.60E-03

100

7.0423

7.52E-08

3.04E-03

1.60E-03

101

7.0845

7.50E-08

3.04E-03

1.60E-03

102

7.1479

7.49E-08

3.04E-03

1.60E-03

103

7.243

7.47E-08

3.04E-03

1.60E-03

104

7.3856

7.47E-08

3.04E-03

1.60E-03

105

7.5856

7.47E-08

3.04E-03

1.60E-03

106

7.7856

7.47E-08

3.04E-03

1.60E-03

107

7.8928

7.47E-08

3.04E-03

1.60E-03

108

8

7.47E-08

3.04E-03

1.60E-03

Simulation Video - https://drive.google.com/file/d/1Sxqocb1vAHVOvaniBBXktZmlvEz3ekCp/view?usp=sharing

Case 2:

Equivalent Stress:

Time [s]

Minimum [MPa]

Maximum [MPa]

Average [MPa]

1

3.50E-02

9.58E-05

293.7

65.777

2

7.00E-02

2.39E-04

340.98

103.83

3

0.1225

1.83E-04

316.73

110.03

4

0.15006

5.59E-04

322.62

112.3

5

0.17762

6.32E-04

317.44

113.87

6

0.20519

8.36E-04

323.32

115.37

7

0.24653

8.04E-04

329.98

116.53

8

0.28787

1.28E-03

339.82

118.15

9

0.30958

1.33E-03

344.15

119.36

10

0.33129

1.56E-03

348.43

120.25

11

0.36384

1.74E-03

354.99

120.95

12

0.41268

2.06E-03

363.78

121.83

13

0.46152

2.31E-03

372.67

123.05

14

0.51036

2.44E-03

380.42

124.5

15

0.536

2.43E-03

384.04

125.67

16

0.56164

2.74E-03

387.47

126.48

17

0.60009

3.07E-03

392.06

126.96

18

0.63855

2.94E-03

399.21

127.65

19

0.67701

3.37E-03

405.77

128.29

20

0.7347

3.44E-03

414.13

128.53

21

0.76499

3.45E-03

418.78

129.51

22

0.79528

3.26E-03

422.9

130.04

23

0.84071

3.66E-03

428.98

129.93

24

0.90885

3.56E-03

436.94

129.65

25

0.977

3.83E-03

443.07

123.3

26

1

4.16E-03

445.3

120.93

27

1.023

4.25E-03

446.78

120.59

28

1.046

4.22E-03

447.88

120

29

1.0805

4.26E-03

449.18

119.24

30

1.1323

4.18E-03

450.12

118.98

31

1.2099

4.77E-03

451.25

118.3

32

1.2875

1.35E-02

451.49

117.55

33

1.404

8.06E-03

451.58

116.87

34

1.5787

5.04E-03

451.9

116.42

35

1.6001

4.48E-03

452.01

116.52

36

1.6215

4.73E-03

449.78

116.29

37

1.6536

6.65E-03

443.81

114.94

38

1.7017

3.61E-03

445.17

114.97

39

1.7739

4.65E-03

413.81

111.76

40

1.8462

5.19E-03

371.42

106.91

41

1.9545

5.06E-03

330.14

101.72

42

2

5.31E-03

337.6

100.22

43

2.0455

4.23E-03

343.57

97.642

44

2.091

4.87E-03

353.66

95.809

45

2.1593

9.33E-03

339.84

93.734

46

2.2617

2.68E-03

329.83

91.828

47

2.364

6.37E-03

326.92

90.677

48

2.5176

5.39E-03

339.73

89.535

49

2.7176

5.59E-03

336.46

88.858

50

2.9176

5.12E-03

339.33

89.043

51

3

4.98E-03

318.39

89.232

52

3.0824

5.67E-03

335.89

89.635

53

3.1648

5.30E-03

317.55

90.032

54

3.2884

9.71E-03

298.7

90.74

55

3.4119

4.49E-03

332.56

91.758

56

3.5973

3.24E-03

301.67

94.011

57

3.7973

3.39E-03

318.13

96.006

58

3.8986

1.11E-02

321.81

96.919

59

4

3.05E-03

306.63

97.918

60

4.1014

3.49E-03

328.85

99.109

61

4.2027

1.78E-03

314.17

100.23

62

4.3547

2.63E-03

321.13

101.24

63

4.5547

3.43E-03

314.61

103.21

64

4.6247

1.75E-03

318.43

103.85

65

4.6947

1.27E-03

310.99

104.25

66

4.7472

2.29E-03

309.95

104.65

67

4.7997

1.63E-03

330.35

104.9

68

4.8785

2.55E-03

312.57

105.35

69

4.9572

3.33E-03

304.23

105.6

70

5

2.11E-03

311.32

105.91

71

5.0428

1.24E-03

351.22

106.42

72

5.0855

1.03E-03

319.75

106.79

73

5.1497

1.07E-03

316.39

106.88

74

5.2139

1.83E-03

322.67

107.15

75

5.3101

1.10E-03

305.83

107.18

76

5.4064

1.11E-02

348.69

108.58

77

5.5507

3.92E-04

308.84

109.09

78

5.6229

6.34E-04

315.32

109.1

79

5.6951

5.72E-04

315.09

109.99

80

5.7492

7.83E-04

317.75

110.25

81

5.8034

1.17E-03

336.88

110.39

82

5.8846

3.93E-04

330.59

111

83

6

2.28E-03

330.11

111.92

84

6.0404

7.94E-04

342.04

112.05

85

6.0808

5.05E-04

343.15

112.13

86

6.1414

9.90E-04

326.04

112.07

87

6.202

1.54E-03

312.6

112.03

88

6.2626

1.66E-03

318.11

112.52

89

6.3535

3.12E-03

334.02

112.96

90

6.4445

3.25E-03

325.8

113.61

91

6.5354

2.41E-03

320.02

114.03

92

6.6263

3.67E-03

324.53

114.53

93

6.6717

2.17E-03

313.25

114.63

94

6.7172

2.31E-03

323.67

114.84

95

6.7627

2.92E-03

322.45

115.14

96

6.8308

2.36E-03

313.98

115.69

97

6.899

3.04E-03

347.36

116.07

98

7

3.22E-03

340.88

116.41

99

7.101

2.97E-03

340.67

116.41

100

7.2019

2.97E-03

340.63

116.4

101

7.3534

2.97E-03

340.63

116.4

102

7.5534

2.97E-03

340.62

116.4

103

7.7534

2.97E-03

340.62

116.4

104

7.8767

2.97E-03

340.62

116.4

105

8

2.97E-03

340.62

116.4

Simulation Video - https://drive.google.com/file/d/1w03zG6pcVFq2QzH4TVllywQqPnclxWlK/view?usp=sharing

Equivalent Elastic Strain:

Time [s]

Minimum [mm/mm]

Maximum [mm/mm]

Average [mm/mm]

1

3.50E-02

2.13E-09

4.14E-03

9.60E-04

2

7.00E-02

3.47E-09

4.81E-03

1.55E-03

3

0.1225

9.22E-09

4.47E-03

1.68E-03

4

0.15006

1.64E-08

4.55E-03

1.72E-03

5

0.17762

1.63E-08

4.52E-03

1.75E-03

6

0.20519

2.01E-08

4.61E-03

1.77E-03

7

0.24653

2.44E-08

4.65E-03

1.80E-03

8

0.28787

3.20E-08

4.79E-03

1.82E-03

9

0.30958

3.40E-08

4.85E-03

1.84E-03

10

0.33129

3.74E-08

4.91E-03

1.86E-03

11

0.36384

4.23E-08

5.00E-03

1.87E-03

12

0.41268

4.93E-08

5.13E-03

1.89E-03

13

0.46152

5.57E-08

5.25E-03

1.91E-03

14

0.51036

6.26E-08

5.36E-03

1.93E-03

15

0.536

6.37E-08

5.41E-03

1.95E-03

16

0.56164

6.91E-08

5.46E-03

1.96E-03

17

0.60009

7.38E-08

5.53E-03

1.97E-03

18

0.63855

7.29E-08

5.63E-03

1.99E-03

19

0.67701

8.15E-08

5.72E-03

2.00E-03

20

0.7347

8.06E-08

5.84E-03

2.00E-03

21

0.76499

8.25E-08

5.91E-03

2.02E-03

22

0.79528

9.77E-08

5.97E-03

2.03E-03

23

0.84071

9.93E-08

6.05E-03

2.03E-03

24

0.90885

8.81E-08

6.17E-03

2.03E-03

25

0.977

1.08E-07

6.28E-03

1.93E-03

26

1

1.05E-07

6.33E-03

1.90E-03

27

1.023

8.69E-08

6.34E-03

1.89E-03

28

1.046

1.07E-07

6.35E-03

1.88E-03

29

1.0805

1.08E-07

6.37E-03

1.87E-03

30

1.1323

9.26E-08

6.38E-03

1.87E-03

31

1.2099

9.86E-08

6.40E-03

1.86E-03

32

1.2875

2.38E-07

6.40E-03

1.85E-03

33

1.404

2.50E-07

6.40E-03

1.84E-03

34

1.5787

8.15E-08

6.41E-03

1.84E-03

35

1.6001

1.22E-07

6.41E-03

1.84E-03

36

1.6215

1.13E-07

6.38E-03

1.84E-03

37

1.6536

1.36E-07

6.30E-03

1.82E-03

38

1.7017

1.30E-07

6.33E-03

1.82E-03

39

1.7739

1.16E-07

5.91E-03

1.78E-03

40

1.8462

1.12E-07

5.30E-03

1.71E-03

41

1.9545

1.08E-07

4.67E-03

1.65E-03

42

2

1.12E-07

4.79E-03

1.63E-03

43

2.0455

1.32E-07

4.88E-03

1.59E-03

44

2.091

1.19E-07

5.02E-03

1.57E-03

45

2.1593

1.59E-07

4.83E-03

1.54E-03

46

2.2617

8.57E-08

4.68E-03

1.52E-03

47

2.364

1.18E-07

4.64E-03

1.51E-03

48

2.5176

1.05E-07

4.82E-03

1.50E-03

49

2.7176

1.07E-07

4.75E-03

1.51E-03

50

2.9176

1.17E-07

4.84E-03

1.52E-03

51

3

1.18E-07

4.49E-03

1.52E-03

52

3.0824

1.12E-07

4.76E-03

1.53E-03

53

3.1648

1.16E-07

4.49E-03

1.54E-03

54

3.2884

2.50E-07

4.21E-03

1.56E-03

55

3.4119

1.14E-07

4.74E-03

1.58E-03

56

3.5973

1.05E-07

4.26E-03

1.62E-03

57

3.7973

1.16E-07

4.51E-03

1.66E-03

58

3.8986

2.05E-07

4.57E-03

1.68E-03

59

4

9.76E-08

4.33E-03

1.70E-03

60

4.1014

9.86E-08

4.69E-03

1.72E-03

61

4.2027

8.46E-08

4.50E-03

1.74E-03

62

4.3547

8.16E-08

4.54E-03

1.76E-03

63

4.5547

1.09E-07

4.45E-03

1.80E-03

64

4.6247

6.87E-08

4.58E-03

1.81E-03

65

4.6947

5.84E-08

4.42E-03

1.82E-03

66

4.7472

6.98E-08

4.40E-03

1.83E-03

67

4.7997

5.22E-08

4.67E-03

1.84E-03

68

4.8785

5.10E-08

4.41E-03

1.84E-03

69

4.9572

5.70E-08

4.30E-03

1.85E-03

70

5

4.93E-08

4.49E-03

1.86E-03

71

5.0428

4.49E-08

5.01E-03

1.87E-03

72

5.0855

3.85E-08

4.54E-03

1.88E-03

73

5.1497

2.84E-08

4.47E-03

1.88E-03

74

5.2139

3.17E-08

4.56E-03

1.89E-03

75

5.3101

2.75E-08

4.35E-03

1.89E-03

76

5.4064

1.69E-07

4.94E-03

1.91E-03

77

5.5507

1.58E-08

4.39E-03

1.93E-03

78

5.6229

1.58E-08

4.49E-03

1.93E-03

79

5.6951

1.11E-08

4.46E-03

1.95E-03

80

5.7492

1.32E-08

4.51E-03

1.95E-03

81

5.8034

1.85E-08

4.80E-03

1.96E-03

82

5.8846

1.32E-08

4.71E-03

1.97E-03

83

6

3.56E-08

4.67E-03

1.99E-03

84

6.0404

1.98E-08

4.84E-03

2.00E-03

85

6.0808

1.17E-08

4.86E-03

2.00E-03

86

6.1414

1.86E-08

4.64E-03

2.00E-03

87

6.202

2.35E-08

4.44E-03

2.00E-03

88

6.2626

2.81E-08

4.51E-03

2.01E-03

89

6.3535

5.58E-08

4.72E-03

2.02E-03

90

6.4445

6.94E-08

4.62E-03

2.04E-03

91

6.5354

6.87E-08

4.52E-03

2.04E-03

92

6.6263

9.32E-08

4.60E-03

2.06E-03

93

6.6717

7.31E-08

4.43E-03

2.06E-03

94

6.7172

7.39E-08

4.58E-03

2.07E-03

95

6.7627

8.44E-08

4.56E-03

2.08E-03

96

6.8308

7.07E-08

4.48E-03

2.09E-03

97

6.899

8.46E-08

4.91E-03

2.10E-03

98

7

8.21E-08

4.84E-03

2.11E-03

99

7.101

7.79E-08

4.84E-03

2.11E-03

100

7.2019

7.78E-08

4.84E-03

2.11E-03

101

7.3534

7.78E-08

4.84E-03

2.11E-03

102

7.5534

7.77E-08

4.84E-03

2.11E-03

103

7.7534

7.77E-08

4.84E-03

2.11E-03

104

7.8767

7.77E-08

4.84E-03

2.11E-03

105

8

7.77E-08

4.84E-03

2.11E-03

Simulation Video - https://drive.google.com/file/d/186ftOAoX3-qDYjnINusGsfEmCNSOTAXZ/view?usp=sharing

Case 3:

Equivalent Stress:

Time [s]

Minimum [MPa]

Maximum [MPa]

Average [MPa]

1

1.00E-02

4.91E-04

65.394

6.7051

2

2.00E-02

3.88E-05

102.47

24.307

3

3.50E-02

2.70E-05

200.22

55.16

4

5.75E-02

3.14E-05

208.53

80.501

5

9.13E-02

8.89E-05

219.28

90.564

6

0.14188

1.06E-03

257.7

96.838

7

0.16845

3.00E-04

264.71

99.697

8

0.19503

2.37E-04

274.32

102.18

9

0.2349

4.54E-04

286.33

105.58

10

0.27477

5.85E-04

307.39

108.67

11

0.33457

7.08E-04

332.39

113.06

12

0.36596

7.15E-04

339.83

115.25

13

0.39736

7.75E-04

346.23

117.37

14

0.44445

8.82E-04

357.71

120.36

15

0.46917

1.05E-03

367.43

121.93

16

0.4939

1.05E-03

372.89

123.38

17

0.53098

1.10E-03

381.55

125.45

18

0.58661

1.47E-03

395.24

128.32

19

0.64224

1.20E-03

408.57

131.06

20

0.69787

1.01E-03

423.27

133.26

21

0.72708

1.44E-03

429.55

134.3

22

0.75628

1.58E-03

435.53

135.26

23

0.80009

1.51E-03

445.91

135.77

24

0.8658

6.27E-03

462.2

134.45

25

0.93151

3.66E-03

477.79

131.91

26

0.96576

1.51E-03

484.79

131.08

27

1

1.55E-03

496.72

127.7

28

1.0342

1.44E-03

498.07

127.63

29

1.0685

1.73E-03

499.12

127.62

30

1.1199

1.39E-03

500.66

126.85

31

1.1712

1.23E-03

502.11

125.71

32

1.2483

1.44E-02

500.48

125.59

33

1.3253

4.10E-03

498.87

125.45

34

1.4409

2.90E-03

495.74

124.37

35

1.4987

1.34E-03

495.69

123.9

36

1.5565

2.02E-03

497.31

123.59

37

1.6432

1.72E-03

492.76

122.68

38

1.7082

1.77E-03

489.6

122.37

39

1.7732

1.94E-03

487.49

121.91

40

1.8382

1.72E-03

481.97

121.16

41

1.9357

2.26E-03

480.26

120.99

42

2

1.72E-03

477.42

120.46

43

2.0643

1.90E-03

442.03

115.97

44

2.1286

1.72E-03

404.27

111.19

45

2.225

1.71E-03

353.81

104.82

46

2.3215

1.72E-03

318.99

100.42

47

2.4179

1.71E-03

294.94

97.739

48

2.5144

1.58E-03

277.5

96.142

49

2.6108

1.67E-03

268.06

95.295

50

2.7072

1.62E-03

260.47

94.297

51

2.8037

1.95E-03

254.08

93.713

52

2.9001

1.49E-03

250.26

93.588

53

2.9501

1.44E-03

249.35

93.63

54

3

1.37E-03

248.58

93.609

55

3.0499

1.30E-03

251.21

93.25

56

3.0999

1.16E-03

249.82

93.38

57

3.1748

1.54E-03

246.29

93.712

58

3.2497

1.43E-03

243.16

93.919

59

3.3246

1.24E-03

242.58

94.516

60

3.3995

9.33E-04

241.61

94.557

61

3.4744

1.00E-03

241.92

94.938

62

3.5493

1.05E-03

243.75

95.346

63

3.6243

1.22E-03

241.67

95.616

64

3.6992

5.45E-04

242.54

96.236

65

3.8115

1.02E-03

243.48

97.57

66

3.9239

1.22E-03

243.01

98.124

67

3.9619

6.49E-04

241.86

98.171

68

4

6.90E-04

243.12

98.661

69

4.0381

9.34E-04

244.95

99.233

70

4.0761

9.23E-04

246.36

99.65

71

4.1332

5.35E-04

282.14

99.488

72

4.2188

1.08E-03

248.22

100.74

73

4.3044

9.37E-04

248.84

101.35

74

4.39

1.08E-03

251.73

102.25

75

4.4328

1.09E-03

251.46

102.5

76

4.4756

8.39E-04

253.26

102.96

77

4.5399

1.07E-03

256.49

103.85

78

4.6041

7.76E-04

260.7

104.75

79

4.6683

1.02E-03

260.38

105.02

80

4.7646

7.27E-04

262.01

105.93

81

4.8609

7.40E-04

262.99

106.58

82

4.9572

3.59E-04

262.88

107.23

83

5

3.61E-04

262.68

107.47

84

5.0428

3.38E-04

262.7

107.72

85

5.0855

3.09E-04

262.89

107.95

86

5.1497

4.87E-04

262.57

108.28

87

5.1978

2.25E-04

262.35

108.59

88

5.2459

2.91E-04

262.52

108.97

89

5.318

1.88E-04

262.7

109.42

90

5.3902

3.34E-04

262.6

109.75

91

5.4624

8.00E-04

262.61

110.33

92

5.5706

8.54E-05

262.76

110.97

93

5.733

1.43E-04

262.16

111.9

94

5.933

6.21E-04

262.17

112.8

95

6

3.70E-04

262.15

113.23

96

6.067

3.63E-04

261.61

113.51

97

6.1341

1.00E-04

261.68

113.82

98

6.2011

3.94E-04

261.42

114.19

99

6.3017

2.53E-03

261.08

114.69

100

6.4022

7.73E-04

261.42

115.28

101

6.5028

2.69E-04

261.14

115.77

102

6.6034

4.97E-03

261.33

116.29

103

6.7039

2.79E-03

260.85

116.78

104

6.8045

2.13E-03

261.32

117.45

105

6.9051

5.02E-04

261.17

118.05

106

7

3.67E-03

261.5

118.58

107

7.0949

6.56E-04

261.21

118.52

108

7.1899

6.61E-04

261.1

118.5

109

7.3323

6.73E-04

261.1

118.5

110

7.5323

6.75E-04

261.11

118.5

111

7.7323

6.75E-04

261.11

118.5

112

7.9323

6.75E-04

261.11

118.5

113

8

6.75E-04

261.11

118.5

Simulation Video - https://drive.google.com/file/d/1sm2uJRFXo1qxNFyJ9pY0DFGJf8txuC79/view?usp=sharing

Equivalent Elastic Strain:

Time [s]

Minimum [mm/mm]

Maximum [mm/mm]

Average [mm/mm]

1

1.00E-02

1.21E-08

1.55E-03

1.53E-04

2

2.00E-02

8.81E-10

2.38E-03

5.50E-04

3

3.50E-02

6.04E-10

4.49E-03

1.24E-03

4

5.75E-02

9.39E-10

4.64E-03

1.83E-03

5

9.13E-02

2.77E-09

5.00E-03

2.08E-03

6

0.14188

3.13E-08

5.80E-03

2.24E-03

7

0.16845

8.75E-09

6.02E-03

2.31E-03

8

0.19503

7.16E-09

6.18E-03

2.37E-03

9

0.2349

1.14E-08

6.48E-03

2.45E-03

10

0.27477

1.49E-08

6.88E-03

2.52E-03

11

0.33457

1.75E-08

7.53E-03

2.62E-03

12

0.36596

2.03E-08

7.68E-03

2.68E-03

13

0.39736

1.85E-08

7.79E-03

2.73E-03

14

0.44445

2.22E-08

8.14E-03

2.80E-03

15

0.46917

2.69E-08

8.20E-03

2.83E-03

16

0.4939

2.64E-08

8.31E-03

2.87E-03

17

0.53098

2.50E-08

8.51E-03

2.92E-03

18

0.58661

3.29E-08

8.81E-03

2.98E-03

19

0.64224

3.13E-08

9.11E-03

3.05E-03

20

0.69787

3.38E-08

9.43E-03

3.10E-03

21

0.72708

3.25E-08

9.56E-03

3.13E-03

22

0.75628

4.26E-08

9.69E-03

3.15E-03

23

0.80009

4.55E-08

9.92E-03

3.16E-03

24

0.8658

1.59E-07

1.03E-02

3.13E-03

25

0.93151

1.13E-07

1.06E-02

3.07E-03

26

0.96576

3.42E-08

1.08E-02

3.05E-03

27

1

3.53E-08

1.11E-02

2.98E-03

28

1.0342

4.83E-08

1.11E-02

2.98E-03

29

1.0685

3.91E-08

1.11E-02

2.98E-03

30

1.1199

5.61E-08

1.11E-02

2.96E-03

31

1.1712

2.84E-08

1.12E-02

2.93E-03

32

1.2483

3.83E-07

1.11E-02

2.93E-03

33

1.3253

1.03E-07

1.11E-02

2.93E-03

34

1.4409

9.76E-08

1.10E-02

2.91E-03

35

1.4987

6.28E-08

1.10E-02

2.90E-03

36

1.5565

4.55E-08

1.11E-02

2.90E-03

37

1.6432

3.89E-08

1.10E-02

2.88E-03

38

1.7082

4.00E-08

1.09E-02

2.87E-03

39

1.7732

4.38E-08

1.09E-02

2.86E-03

40

1.8382

3.90E-08

1.08E-02

2.85E-03

41

1.9357

5.41E-08

1.07E-02

2.85E-03

42

2

3.90E-08

1.07E-02

2.84E-03

43

2.0643

4.33E-08

9.87E-03

2.74E-03

44

2.1286

3.90E-08

9.03E-03

2.63E-03

45

2.225

3.88E-08

7.90E-03

2.50E-03

46

2.3215

3.90E-08

7.12E-03

2.40E-03

47

2.4179

3.89E-08

6.58E-03

2.35E-03

48

2.5144

4.18E-08

6.19E-03

2.32E-03

49

2.6108

4.95E-08

5.96E-03

2.30E-03

50

2.7072

5.95E-08

5.79E-03

2.28E-03

51

2.8037

8.43E-08

5.65E-03

2.27E-03

52

2.9001

3.73E-08

5.57E-03

2.28E-03

53

2.9501

3.69E-08

5.55E-03

2.28E-03

54

3

3.70E-08

5.54E-03

2.28E-03

55

3.0499

4.37E-08

5.60E-03

2.27E-03

56

3.0999

4.16E-08

5.56E-03

2.28E-03

57

3.1748

6.68E-08

5.49E-03

2.29E-03

58

3.2497

6.62E-08

5.42E-03

2.30E-03

59

3.3246

3.74E-08

5.40E-03

2.31E-03

60

3.3995

3.62E-08

5.39E-03

2.32E-03

61

3.4744

3.73E-08

5.40E-03

2.33E-03

62

3.5493

3.90E-08

5.44E-03

2.34E-03

63

3.6243

5.54E-08

5.38E-03

2.35E-03

64

3.6992

3.02E-08

5.40E-03

2.37E-03

65

3.8115

3.59E-08

5.42E-03

2.40E-03

66

3.9239

5.12E-08

5.40E-03

2.42E-03

67

3.9619

3.05E-08

5.39E-03

2.42E-03

68

4

3.13E-08

5.41E-03

2.43E-03

69

4.0381

3.95E-08

5.45E-03

2.45E-03

70

4.0761

3.49E-08

5.48E-03

2.46E-03

71

4.1332

2.87E-08

6.33E-03

2.46E-03

72

4.2188

4.27E-08

5.52E-03

2.49E-03

73

4.3044

3.05E-08

5.53E-03

2.51E-03

74

4.39

3.21E-08

5.60E-03

2.53E-03

75

4.4328

3.34E-08

5.59E-03

2.54E-03

76

4.4756

2.29E-08

5.63E-03

2.55E-03

77

4.5399

3.00E-08

5.70E-03

2.57E-03

78

4.6041

1.90E-08

5.80E-03

2.59E-03

79

4.6683

2.59E-08

5.79E-03

2.60E-03

80

4.7646

1.83E-08

5.83E-03

2.63E-03

81

4.8609

1.88E-08

5.85E-03

2.65E-03

82

4.9572

1.15E-08

5.85E-03

2.67E-03

83

5

1.27E-08

5.84E-03

2.67E-03

84

5.0428

1.16E-08

5.84E-03

2.68E-03

85

5.0855

1.14E-08

5.85E-03

2.69E-03

86

5.1497

1.81E-08

5.84E-03

2.70E-03

87

5.1978

1.74E-08

5.83E-03

2.71E-03

88

5.2459

1.76E-08

5.84E-03

2.72E-03

89

5.318

1.80E-08

5.84E-03

2.73E-03

90

5.3902

1.83E-08

5.84E-03

2.74E-03

91

5.4624

1.92E-08

5.84E-03

2.75E-03

92

5.5706

4.43E-09

5.84E-03

2.77E-03

93

5.733

4.42E-09

5.83E-03

2.80E-03

94

5.933

3.20E-08

5.83E-03

2.83E-03

95

6

1.14E-08

5.83E-03

2.84E-03

96

6.067

9.73E-09

5.82E-03

2.85E-03

97

6.1341

3.00E-09

5.82E-03

2.86E-03

98

6.2011

1.05E-08

5.81E-03

2.87E-03

99

6.3017

7.09E-08

5.81E-03

2.89E-03

100

6.4022

1.96E-08

5.81E-03

2.91E-03

101

6.5028

1.06E-08

5.81E-03

2.92E-03

102

6.6034

1.28E-07

5.81E-03

2.94E-03

103

6.7039

6.64E-08

5.80E-03

2.95E-03

104

6.8045

6.22E-08

5.81E-03

2.97E-03

105

6.9051

1.58E-08

5.81E-03

2.99E-03

106

7

9.63E-08

5.82E-03

3.01E-03

107

7.0949

2.03E-08

5.81E-03

3.01E-03

108

7.1899

2.04E-08

5.81E-03

3.01E-03

109

7.3323

2.04E-08

5.81E-03

3.01E-03

110

7.5323

2.04E-08

5.81E-03

3.01E-03

111

7.7323

2.04E-08

5.81E-03

3.01E-03

112

7.9323

2.04E-08

5.81E-03

3.01E-03

113

8

2.04E-08

5.81E-03

3.01E-03

Simulation Video - https://drive.google.com/file/d/1nB2lLrHPEfAJIWbDrY6e95_9JDt1usDe/view?usp=sharing

Tabulation:

Cases

Max. Equivalent Stress (MPa)

Max. Equivalent Elastic Strain (mm/mm)

Case 1

650.38

5.96E-03

Case 2

452.01

6.41E-03

Case 3

502.11

1.12E-02

Comparison:

From the simulation results we can see that the Case 2 material that is Aluminium Alloy NL has experienced least Max. Equivalent Stress compared to the other materials Copper Alloy NL and Magnesium Alloy NL. Even though Aluminium Alloy NL has experienced a bit higher Max. Equivalent Elastic Strain than Copper Alloy NL, we can see that the latter has experienced larger Max. Equivalent Stress. So, we can conclude that Aluminium Alloy NL is the better material suited for Wire Bending process out of the given materials.

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