Week 4 -Wire Bending Challenge

Objective:

To perform an analysis to simulate the bending of a wire in ANSYS,for which we will have to use Copper Alloy (Non Linear), Aluminium Alloy (Non Linear) and Magnesium Alloy ( Non Linear) for the wire alone. We need to find out the Equivalent stress and Equivalent strain on the wire alone and Compare out the results.

Case Setup & Procedures:

• In the engineering data source of static structural analysis we have selected the materials like Cu Alloy NL, Al Alloy NL & Mg Alloy NL.     
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• The CAD geometry has been imported and the material has been assigned to the wire for simulating the bending process. The lever and the Die has been assigned as a structural steel material.
• In the connection region we have assigned  a revolute joint for the lever and a frictional contact between the wire and the lever and wire and the wheel is assigned to them as shown below.     

                 

• In the mesh column we have assigned  face sizing to the wire and the contact region of lever and wheel with wire as element size of 2.2mm. We have even assigned a sphere of infulence at the bend portion by using generating a new cooridinate with radius of sphere as 7 mm.

      

• In the analysis setting we have assigned 8 steps and other settings are shown as below. 
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• In order to simulate the bending analysis we have applied fixed support to the wheel and we have also fixed one end of the wire so that the wire should wire should not move away from its positions.                                         
• For the lever we have applied a joint load in the form of rotation and the rotation is applied in the   anticlockwise direction in a increasing step of 20 degree as shown below.      
• In the solution section we are looking for equivalent stress and equivalent strain on the wire.

Results:

Case 1 (Cu Alloy)

Equivalent stress

Equivalent strain.

Case 2 (Al Alloy)

Equivalent stress 

Equivalent strain.    

Case 3 (Mg Alloy)

Equivalent stress 

Equivalent strain.

Discussion & Conclusion:

wire material	Equivalent Stress MPa	Equivalent Strain mm/mm
Case 1 (Cu Alloy)	325.16 MPa	.003036
Case 2 (Al Alloy)	303.43 MPa	.004305
Case 3 (Mg Alloy)	256.32 MPa	.005719

• From the above table it can be observed that the maximum equivalent stress is observed in Cu Alloy followed by Al and Mg Alloy.
• The equivalent strain is maximum in case of Mg alloy and least in case of Cu Alloy.
• Thus Mg has the ability to undergo plastic deformation more eaisly compare to Al and Cu Alloy.

https://drive.google.com/file/d/1CbA5PHMDXpqYOVA4gZCmCsd8Pm3wKB4m/view?usp=sharing