Week 4 -Wire Bending Challenge

Objective: To find the Equivalent stress and Equivalent strain on the wire alone for materials

1) Aluminium Alloy (Non Linear),

2) Copper Alloy (Non Linear) and

3) Magnesium Alloy ( Non Linear)

and compare the results for each case.

CASE: 1

Setup:

Engineering data: 

Aluminium alloy NL

Geometry:

• exported file of wire bending model.x_t
• Edit Geometry in spaceclaim: no change in model

Model:

Geometry: renamed parts as wheel, wire (material= Aluminium alloy), lever

Material: no change

Coordinate system: 

• Global Coordinate system 
• Coordinate system 

Connections: 

Contacts:

• Frictional: Wheel to Wire
• Frictional: Wire to lever

Joints:

• Revolute: Ground to lever

Mesh:

• Patch confirming method: tetrahedron 
• Face sizing: 2.2 to four critical faces 
• Face sizing 2:  wire face ( Sphere of influence,  Coordinate system, radius 7, size 0.8)
• Smoothing : low

Static structural:

• Analysis setting:

1st Step:

1.        Number of steps =08
2.        Current step number = 1
3.        Step end time = 1 s
4.        Auto time stepping = On
5.        Define by = Time
6.        Initial Time step = 0.1s
7.        Minimum time step = 1.e-002s
8.        Maximum time step = 1s
9.        Weak springs = On
10.        Spring stiffness = Factor
11.        Spring stiffness factor= 0.1
12.        Large deflection: On
13.        Output controls: All yes

Remaining Steps:

1.        Number of steps =08
2.        Current step number = multistep
3.        Step end time = multistep
4.        Auto time stepping = Program controlled
5.        Weak springs = On
6.        Spring stiffness = Factor
7.        Spring stiffness factor= 0.1
8.        Large deflection: On
9.        Output controls: All yes

• Fixed support

1. Geometry = 1 face of Wheel
2. Type = fixed support

• Fixed support

1. Geometry = 1 face if workpiece 
2. Type = fixed support

• Joint-Rotation:

1. Cylindrical: Ground to lever
2. DOF: Rotation Z
3. Type: Rotation 
4. Magnitude: tabular

Similarly for...

CASE: 2  Copper alloy

CASE: 3  Magnesium alloy

Case 1 Solution: Aluminium alloy

1. Equivalent stress

2. Equivalent elastic Strain

Case 2 Solution: Copper alloy

1. Equivalent stress 

2. Equivalent elastic Strain

Case 3 Solution: Magnesium alloy

1. Equivalent stress 

2. Equivalent elastic Strain

Comparision of three material wrt Maximum stress