Week 4 -Wire Bending Challenge

REPORT

WIRE BENDING

OBJECTIVE

To perform static structural analysis on bending of a wire and to compare the results of 3 different materials on the wire.

PROCEDURE

CASE 1

The model in mechanical GUI is shown below,

Copper alloy NL is the material used in case 1 for wire, and the properties of the material is shown below.

Define two contacts one is between wire and lever and other is between wheel and wire.

Both contact is frictional and a frictional coefficient of 0.2 is given, other given parameters are follows,

For mesh, tetrahedron mesh is given to three parts, in quality set smoothening to low and size of 2.2mm is given to faces that shows below.

A0.8mm mesh is given to wire covering the sphere below,

The generated mesh looks like below,

ANALYSIS SETTING

Total 8 steps.

Step 1

Output controls to all yes.

Step 2-8

STATIC STRUCTURAL

The wheel and flat face of wire is fixed.

The lever is given a revolute joint and rotated to 140 degree clockwise.

SOLUTION

Requested for equivalent stress, equivalent strain for wire only and total deformation for whole model because to see the whole animation.

RESULTS

The equivalent stress and strain on the wire is shown below,

CASE 2

Here the material used for wire is aluminium alloy NL and its properties are shown below,

All other procedures are same as case 1.

The results are shown below,

CASE 3

Here the material used for wire is magnesium alloy NL and its properties are shown below,

All other procedures are same as case 1.

The results are shown below,

Comparing the results

CASE EQUIVALENT STRESS(MAX) EQUIVALENT STRAIN (MAX)

1 337.28 MPa 0.0031662

2 321.94 MPa 0.0045505

3 255.14 MPa 0.0056903

CONCLUSION

The maximum equivalent stress is developed in copper alloy NL and minimum equivalent stress is developed in magnesium alloy NL.

The maximum strain is developed in magnesium alloy NL and minimum in copper alloy NL.

Magnesium requires less force for bending operation.