Week 4 -Wire Bending Challenge

Objective: To simulate wire bending and calculate equivalent stress and strain values on wire using copper non linear, aluminium non linear and magnesium non linear materials

Setting up analysis: Open ANSYS workbench and selected static structural and imported the geometry. Selected required materials from engineering data. The materials are Aluminum,Copper and Magnesium non linear alloys. The model is opened in ANSYS mechanical and according to different cases the material is assigned to only wire.

The names of the different parts of geometry are changed, the names of the parts are wire, wheel and lever and the contact pairs are assigned

The contact settings given are as follows

A revolute joint is assigned to lever as it rotates. The coordinate axes are also changed.

Mesh: The enitre body is selected and meshed with tetrahedron method and change the smoothing to low in mesh quality section

Then face sizing option is selected and the faces which come into contact with eachother are selected and elemnts size of 2.2 mm is given.

A local coordinate system is added at the point shown below with offsets in X and Z direction of 3mm and -3mm

Another face sizing is added and this time the element type is selected by sphere of influence

Boundary conditions: Fixed supports are given to the wheel and tip of the wire

Rotation is given to the revolute joint in 8 steps

Analysis settings:

For 1st time step

for the time steps 2 to 8

Solution:

Case 1: Copper Non linear alloy

Equivalent stress on wire

Equivalnt strain on wire

Case 2: Aluminium Non linear alloy

Equivalent stress on wire

Equivalnt strain on wire

Case 3: Magnesium Non linear alloy

Equivalent stress on wire

Equivalnt strain on wire

Result:

The results obtained are tabulated below as follows

Material	Equivalent stress(Mpa)	Equivalent strain
Copper Non linear alloy	323	0.0029
Aluminium Non linear alloy	321	0.0045
Magnesium Non linear alloy	264	0.0058

Conclusion:

From the tabular data we can observe that Magnesium NL alloy has least amount of stresses developed.