Week 4 -Wire Bending Challenge
AIM:
Wire bending process to be simulated in the Ansys workbench using three different materials
OBJECTIVE:
The main objective of the challenge is to compare the result for Equivalent stress and Strain on the wire only using three different materials.
1) Copper Alloy (Non-Linear)
2) Aluminium Alloy (Non-Linear)
3) Magnesium Alloy (Non -Linear)
PROPERTIES of MATERIAL USED:
PROCEDURE
SIMULATION SETUP
For setting up the simulation process for wire bending, first adding all three materials to the engineering data, then importing the model to the geometry for checking any irregularities or the surface damage of the geometry.
Contact:
As the model has contacts but they are Flip over the target and renamed based on the definition, As the first contact is between the wire as contact bodies and the wheel as target bodies, which is the frictional type with a friction coefficient of 0.2, the formulation method is Augmented LaGrange, Normal stiffness as a factor 0.1, update stiffness at Each iteration, and interface treatment as Add offset
The First contact is between wire to lever:
The second contact: Wheel to wire
A revolute Joint is provided to the base of the wheel so it can revolve while bending the wire but the coordinated system should be given properly so it can revolve in the right direction.
Mesh:
This component is a solid part, tetra mesh can be generated, and to have the accurate result the mesh is refined at the wire and bending source by giving the face sizing. First, the Patch conforming method is inserted by selecting all three bodies and methods as Tetrahedrons:
The face sizing 1 with selecting 4 faces and element size 2.2mm & face sizing 2 with selecting 4 faces, sphere radius 7mm, and element size 0.8mm:
Analysis settings:
A total of 8 steps are provided to run the simulation but step 1 has different parameters with an initial time step 0.1 s, minimum time step 1e002 s, and final time step 0.2 s. From step 2 to 8 as carryover, the time step is ON with minimum time step is 1 e-002 s and maximum time step 1 s.
The fixed support is given to the wheel which is connected to a wire and another fixed support to the top of the wire so while bending it should not get outside of the process to fail the simulation.
RESULTS:
Equivalent_Stress:
Equivalent_Strain:
CONCLUSION:
G-Drive File Link: https://drive.google.com/file/d/1CprW4fMrPD-Y41PYwPfF7IaPc0wijrAc/view?usp=sharing