Week 4 -Wire Bending Challenge
Objective:
You will have to perform an analysis to simulate the bending of a wire in ANSYS. You will have to use Copper Alloy (Non Linear), Aluminium Alloy (Non Linear) and Magnesium Alloy ( Non Linear) for the wire alone.
Solution:
-Firstly, we import the geometry to ANSYS workbench but, before that we add the respected materials to our library.
-We import the geometry and assign copper alloy NL, Aluminium alloy NL and Magnesium alloy NL to the wire for each and every simulation we run.
-Now, we give contacts to the geometry where there are required.
-We, change the contacts from bonded to frictional and give frictional coefficient as 0.2, change the formula to Augmented lagrange.
-Now, we provide joint loads to the geometry where they are required.
-Now, We need to assign proper mesh to the geometry. Where, the contact faces will have 2.2mm of element size and the rest of the geometry will be having default mesh size.
-And also at the area of bend for the wire the mesh size will be of 0.8mm
-Now, we have to provide the boundary conditions to the simulation with analysis settings.
-The above figure states the boundary condition for step_1 and the below figure states the boundary condition for step_2-8.
-Now, we provide supports for the geometry and also the revolution joints too.
-Now, finally we prove the output parameters to the analysis and run the simulation.
Copper Alloy NL
Equivalent Elastic Strain
Equivalent Elastic Strain graph
Equivalent Stress
Equivalent Stress graph
Aluminium Alloy NL
Equivalent Elastic Strain
Equivalent Elastic strain graph
Equivalent Stress
Equivalent Stress graph
Magnesium Alloy NL
Equivalent Elastic Strain
Equivalent Elastic Strain graph
Equivalent Stress
Equivalent Stress graph
Comparision Table:
Equivalent Elastic Strain(mm/mm) Equivalent Stress(MPa)
Coppper Alloy NL 0.0030505 332.31
Aluminium Alloy NL 0.0047792 336.54
Magnesium Alloy NL 0.0057514 258.17
Conclusion:
From the above table we can say that the Aluminium alloy has higest Equivalent Stress and the magnesium alloy has the highest Strain. When compared in between these three materials while bending of a wire.