Week 4 -Wire Bending Challenge

Aim of the project:

To perform the static structural analysis to simulate the bending of wire.

Compare the results for Von-mises stress, and Equivalent elastic strain in varied material conditions of workpiece like Copper alloy, Aluminum alloy and Magnesium alloy.

Set Up

1. In the Ansys workbench we chose static structural analysis and in engineering data we kept material structural steel and along with that we added material Aluminum alloy, Copper alloy and Magnesium alloy.
2. After Importing Wheel, Lever and wire assembly model in the Geometry, We opened Mechanical module by clicking Edit to the model tab.
3. Renamed the models accrdingly and assigned the material Copper alloy to the wire for the first set of analysis.
4. We selected 2 frictional contacts,between Wire - Lever and also between Wheel- wire as shown below.
5. We also specified the revolute joint Ground to Lever as shown below and set it with proper direction.
6. We have adapted 3 different mesh sizing For lever feces and for wire we kept element size 2.2mm, with the help of coordinate sytem with the sphere influence type of face sizing for critical areas of wire we set element size of 0.8mm, Below shown the meshing.
7. In the analysis settings we added Fixed support for the hole in Wheel as shown below. Also we fixed the end face of Wire to avoid movement of the same.
8. Then comes the Joint load, so that wheel rotates in 8 steps with the increment angle of 20 degrees.
9. Finally we requested the solution for Von-mises stress and Equivalent strain and got the results as shown below.
10. Finally we repeated the same simulation with the different set of material for Wire and tabulated the results as shown below.

    Material	Von-mises Stress (Mpa)	Equivalent Strain mm/mm
    Aluminum Alloy 1199	Min. 0.0025072 Max. 324.51	Min. 1.2606e-8 Max. 0.004697
    Copper Alloy NL	Min. 0.0036482 Max. 328.67	Min. 2.6215e-8 Max. 0.0040212
    Magnesium Alloy NL.	Min. 0.0014989 Max. 246.41	Min. 1.3871e-8 Max. 0.0054934

11. As shown in the result Stress generated in the Magnasium alloy wire is very less when compared to copper and aluminium wire, so that we can say Magnasium alloy is more Ductile when compared to copper and aluminum. So we can consider Magnasium alloy as best material for bending process.