Week 4 -Wire Bending Challenge

Aim:

Perform an analysis to simulate the bending of a wire in ANSYS. Use Copper Alloy (Non Linear), Aluminium Alloy (Non Linear) and Magnesium Alloy ( Non Linear) material wire. find out the Equivalent stress and Equivalent strain on the wire alone. Compare the results.

Procedure:

Assign material as Copper Alloy (Non Linear), Aluminium Alloy (Non Linear) and Magnesium Alloy ( Non Linear) from General non material list of materials. Now add a static structural simulation and change material of wire as Copper Alloy (Non Linear) for case 1.

Open the model in space claim module to check for any abnormalities in the model.

Connections :

Contacts 1. Frictional between wire and lever

Contacts 2. Frictional between Wire and Roller and keep the settings as bleow for both:

Joints 1 : Revolute Joint of Lever with ground with settings as below:

Meshing :

Insert the method of meshing to be tetrahedron for all bodies in the assembly.

Insert the sizing for wire and contacting surface of roller as 2.2 mm element size.

Create a new coordinate system at the edge of the roller where the bending of wire takes place. Taking the offset of x and y axis of the selected face.

Insert the sizing for edge of roller where wire bends as sphere of influence type. With sphere radius 6mm and element size 2.2 mm. Here keep the centre of sphere at the edge of roller where the bending of wire happens by selecting new coordinate system created before.

Analysis settings :

Supports :

Keep fixed support for roller by selecting the inner surface of the roller.

Keep fixed support for the wire by selecting the end of wire which is inside the roller slot.

Insert a joint with rotation type having tabular data in clock wise direction.

Solutions :

Insert the Equivalent Elastic Strain and Equivalent Stress on the wire by selecting the geometry as wire body.

Insert the Total Deformation of the Assembly.

Run the Simulation.

For other cases go to workbench and duplicate the static structural module and rename as case 2 and case 3 and follow the same above step but change the material of wire as per case requirement crieterias.

Results:

Copper Wire :

Total Deformation:

Equivalent Stress:

Equivalent Strain:

Magnesium Wire:

Aluminum Wire :

Tabular Result comparision :

	Equivalent Stress (MPa)		Equivalent Strain		Total Deformation (mm)
	Max	Min	Max	Min	Max	Min
Copper Wire	332.7	1.2 e-8	3 e-3	7.3 e-13	262.34	0
Magnesium Wire	260.1	1.4 e-8	6.1 e-3	1.8 e-12	262.64	0
Aluminum Wire	313.56	1.4 e-8	4.4. e-3	7.7 e-13	262.64	0

Conclusion :

Equivalent Stress : The maximum stress developed is in Copper Wire.

Equivalent Strain : The Maximum Strain developed is in Magnesium Wire.

Total Deformation : The deformation in all material wire is same.

Final Result : The Magnesium material wire is easily deformable generating less stress.