Week 4 -Wire Bending Challenge

objective: To perform the ansys workbench simulation for the wire bending process for 3 different materials of wires.

case setup and execution:

The ansys workbench window is opened and static structural is selected. The given wire bending CAD model is imported in the geometry and is edited using spaceclaim.

Materials to be used for the simulation of the wire bending are selected in engineering materials. The chosen materials are as follows.

The wheel and the lever are assigned structural steel as their material. only the material of the wire is changed according to the case as per the problem definition.

The contacts are defined as follows.

Both the contacts are set to be frictional with coefficient of friction as 0.2 ;

augmented lagrange is set as the solver type and large deflections are set on.

The mechanism is set in a way that the wheel is stationary or fixed and the lever is rotated about its center of rotation at the slotted side.

Meshing is done in a way that the most important contact points as shown below have the most refined meshing.

Analysis setup is done with 8 time steps. first step alone is defined by a way and second and further steps are defined in a as shown in the subsequent images.

Fixed support is given for the inner surface of the hole in the wheel as the wheel is kept stationary. Also the end of the wire in the slot of the wheel is set to be a fixed end or else during simulation the wire might slip out wj=hich should not happen as required bending cannot be achieved if that is the case.

Joint load is selected and rotation is selected for the revolute joint. the tabular data is fed in denoting the required angle of rotation in the time steps selected.

The solver is selected for equvalent strain and stress for the wire alone to be solved in this simulation.

case 1 result:

The material of the wire is "COPPER ALLOY NL".

case 2 results:

Material of the wire is "ALUMINIUM ALLOY NL".

case 3 results:

Material of the wire is "MAGNESIUM ALLOY NL"

Tabulation and conclusion:

MATERIAL OF THE WIRE	EQUIVALENT STRESS (MPa)	EQUIVALENT STRAIN
COPPER ALLOY NL	322.72	0.0029691
ALUMINIUM ALLOY NL	313.65	0.0045265
MAGNESIUM ALLOY NL	229.83	0.0051623

It is clear from the results obained that the COPPER ALLOY NL material is more resistant to bending and higher stress is developed for the lowest strain.

the order of resistance to bending is as follow;

COPPER ALLOY NL > ALMINIUM ALLOY NL > MAGNESIUM ALLOY NL.