Week 4 -Wire Bending Challenge
Objective of challenge: To perform the simulation of the bending of a wire by applying materials of Copper Alloy (Non Linear), Aluminium Alloy (Non Linear) and Magnesium Alloy ( Non Linear) for the wire alone. Find out the Equivalent stress and Equivalent strain on the wire alone.
Simulation setup configuration as follows:
1. Model as follows
2. Part names are specified as
3. Material applied for Case 1 Wheel and Lever is "Structural steel" and Wire is "Copper Alloy (Non Linear)".
Case 2 Wheel and Lever is "Structural steel" and Wire is "Aluminium Alloy (Non Linear)".
Case 3 Wheel and Lever is "Structural steel" and Wire is "Magnesium Alloy ( Non Linear)".
4. Connections configured for 3 cases as
5. Mesh size configured for case 1 and 2 as follows
case 1, 2 and 3 Patch conforming method: Applied "Tetrahedrons" for 3 bodies.
case 1, 2 and 3 Face sizing: Applied for 2 surfaces as shown in below image.
case 1, 2 and 3 Face sizing 2: Applied shown in below image.
For case 1 and 2
For Case 3
6. Analysis settings configured as shown in below image.
For Case 1 and 2
Analysis settings for Case 1 and Case 2 configured as shown in below image
Analysis settings for Case 3 configured as
Simulation results are as follows:
| Description | Case studies | |
| Results | Equivalent stress on the wire | Equivalent strain on the wire |
| Case 1 Copper Alloy (Non Linear) |
Max 336.25 Mpa |
Max 0.0030862  |
| Case 2 Aluminium Alloy (Non Linear) |
Max 324.2 Mpa |
Max 0.004597 |
| Case 3 Magnesium Alloy ( Non Linear) |
Max 240.84 Mpa |
Max 0.0053644 |