(ANSYS_P8) -Wire Bending Challenge

OBJECTIVE: To perform an analysis to simulate the bending of a wire in ANSYS.

ANALYSIS

An analysis is done on a bending wire by varying three different wire materials and analysing them based on their equivalent strain and stresses.

MATERIAL AND THEIR PROPERTIES

Stainless Steel-(Wheels)

Density: 7850 kg/m^3

Youngs Modulus: 200000Mpa

Poisson Ratio: 0.3

Tensile Yield Strength: 250 Mpa

Copper Non-Linear (Workpiece )

Density: 8300 kg

Youngs Modulus: 110,000 Mpa

Poisson Ratio: 0.34

Tensile Yield Strength: 280 Mpa

Magnesium Non-Linear (Workpiece )

Density: 1800 kg

Youngs Modulus: 45,000 Mpa

Poisson Ratio: 0.35

Tensile Yield Strength: 193 Mpa

Aluminium Non-Linear (Workpiece )

Density: 1800 kg

Youngs Modulus: 71,000 Mpa

Poisson Ratio: 0.33

Tensile Yield Strength: 280Mpa

MESHING

Meshing is done by setting a method using tetrahedron elements

• A sizing of 2.2mm is set to critical faces on the wire wheel and lever
• A coordinate system is created on an area around the wire and meshing is set using a sphere of influence with raduis of 7mm and element size of 0.8
• 
• A general default mesh is made for the remaining faces and can be seen below
• 

PROCEDURE

CONTACT

• The contacts between the wheels and the wire are specified with frictional type connection.
• Two cantacts are set : Wheel (contact) ,wire (target) : lever (target), wire (contact)
• Friction value of 0.2
• Augumental Langrange
• Normal Stiffness factor of 0.1
• Update stiffness by each iteration
• Interface treatment of add offset and ramped effect

ANALYSIS SETTING

8 STEPS ARE USED

For step 1,

• Auto Time Stepping: On
• Defined by : Time
• Initial time : 0.1
• Minimum time : 0.01
• Maximum time : 0.2
• Solver Type : Direct
• Weak Spring :Controlled
• Large deflection: ON

For step 2-8,

• Auto Time Stepping: On
• Defined by : Time
• Carry on time: ON
• Minimum time : 0.01
• Maximum time : 0.2
• Solver Type : Direct
• Weak Spring :Controlled
• Large deflection: ON
• Output controls : Set all to YES

BOUNDARY CONNECTIONS

1. Joint set was the fixed support on the wheel and the left end of the wire
2. Revoulte joint on the lever.
3. Rotation joint load is defined specifying the rotation

RESULTS

Equivalent Stress Aluminium

Equivalent Strain Alumimium

Equivalent Stress Magnesium

Equivalent Strain Magnesium

Equivalent Stress Copper

Equivalent Strain Copper

MATERIAL	STRESS (Mpa)	STRAIN	YOUNG MODULUS (Mpa)
COPPER	329.13	0.0031	110000
ALUMINIUM	321.44	0.0045	71000
MAGNESIUM	262.36	0.0059	45000

DISCUSSION

The higher the young modulus of a material , the stiffer it is. When a material is stiff , more equivalent stresses would be developed as a result to resistance to deformation. This theory is proven as copper developed the highest stresses and magnesium the least . The copper wire can be said as the strongest among the three because it withstood deformation the most compared to the other two. Maximum stresses was developed at the curve edge of the wheel.

CONCLUSION

This simulation was run succefully and the copper material was found to withstand deformation the most.

Files ccan be accessed through my google drive here

https://drive.google.com/file/d/1vXjeysi5qdb0-TySGRKLx9VmwIqhFc-j/view?usp=sharing

https://drive.google.com/file/d/1wRpi7D7gQnxwYsRv0mrro-87dFyGhIiN/view?usp=sharing

https://drive.google.com/file/d/10LQeptInW0VGph2GwbDAOHvwk3o_-n-G/view?usp=sharing