Week 4 -Wire Bending Challenge
Wire Bending Challenge
Objective:
To perform an analysis to simulate the bending of wire for three different non linear alloy materials for the wire (Copper alloy, Aluminum alloy & magnesium alloy) & to compare their Equivalent strains & Equivalent stresses on the wire alone.
Geometry:
The geometry consists of a wheel, a wire & a lever as shown above.
Contacts:
Frictional contact between wire & lever as shown above.
Frictional contact between wheel & the wire as shown above.
Frictional coefficient of 0.2.
Augmented Lagrange advanced formulation, normal stiffness factor of 0.1 & interface treatment set to add offset, ramped effects.
Joints:
Ground to lever revolute joint is defined as shown above. The co-ordinate system is defined as shown above.
Mesh:
Mesh metrics is shown above.
A face sizing of 1.2mm is assigned to the above highlighted surfaces.
Create coordinate system near the wheel bend & define face sizing by sphere of influence.
Sphere radius being 7mm & face sizing being 0.5mm as shown above.
Smoothing is reduced to low.
No of Nodes: 26968
No of Elements: 14546
Analysis Setting:
The first load step has a settings as shown above. All the output controls are turned on.
All the remaining load steps are assigned the above settings & output controls are turned on.
Boundary Conditions:
The wheel center surface is fixed as shown above.
The wire end surface is fixed as shown above.
The joint load is assigned as shown in the above tabular data. Rotation along Z axis of lever center.
Case 1: Copper Alloy NL as wire material.
Material Data:
Structural steel is used as material for wheel & the lever and its properties are shown above.
Copper Alloy NL material data is shown above. It is used as material for the wire.
Force Convergence & Time Increment:
Force convergence & Time increment from the solution information is shown above.
Result:
Equivalent Elastic Strain:
The wire has a maximum equivalent strain of 0.00312 mm/mm as shown above.
Equivalent Stress:
The wire has a maximum stress of 331 Mpa at the region shown above.
Case 2: Aluminum Alloy NL as wire material
Material Data:
Structural steel is used as material for wheel & the lever and its properties are shown above.
Aluminum Alloy NL material data is shown above. It is used as material for the wire.
Force Convergence & Time Increment:
Force convergence & Time increment from the solution information is shown above
Result:
Equivalent Elastic Strain:
The wire has a maximum equivalent strain of 0.00481 mm/mm as shown above.
Equivalent Stress:
The wire has a maximum stress of 338 Mpa at the region shown above.
Case 3: Magnesium Alloy NL as wire material
Material Data:
Structural steel is used as material for wheel & the lever and its properties are shown above.
Magnesium Alloy NL material data is shown above. It is used as material for the wire.
Force Convergence & Time Increment:
Force convergence & Time increment from the solution information is shown above
Result:
Equivalent Elastic Strain:
The wire has a maximum equivalent strain of 0.00837 mm/mm as shown above.
Equivalent Stress:
The wire has a maximum stress of 314 Mpa at the region shown above.
Comparison:
|
Equivalent Elastic Strain |
Equivalent Stress |
|
|
Case 1 |
0.00312 |
331 |
|
Case 2 |
0.00481 |
338 |
|
Case 3 |
0.00837 |
314 |
From the above table, Equivalent Strain is maximum seen in Case 3(Magnesium Alloy NL) whereas Case 1(Copper Alloy NL) exhibits least strain as seen above.
On the contrary, Case 3(Magnesium Alloy NL) exhibits least Equivalent Stress whereas Case 2(Aluminum Alloy NL) exhibits maximum stress as seen above.
From the above it is clear that for Magnesium Alloy NL, the stress is minimum & hence best suited.
Link to the simulation files: https://drive.google.com/file/d/16-Z4bDpLYGe1Ju_DYufji4ZBHuYBrf3S/view?usp=sharing