Week 4 -Wire Bending Challenge

#4 Week Assignment- Introduction to Ansys Workbench

Aim: To perform an analysis to simulate the bending of a wire in Ansys.

Objective: To analyse bending of a wire in Ansys using 3 different non-linear materials Copper Alloy, Aluminium Alloy, Magnesium Alloy.

• Import the geomtery into the mechanical module of Ansys Workbench under the static structural analysis.

• Assign the material to the wire as Aluminium Alloy NL.
• Goto contacts and remove the unnecessary contacts 1&2, now duplicate the contact3. Flip thedefinition for the duplicated contact.
• Now rename the contacts based on their definition.

• Insert a sizing and select the faces that comes to contact during simulation and assign element size of 2.2mm.

• Insert the sizing and select the type as sphere of influence and the co-ordinate system created with the sphere radius of 7mm and element size of 0.8mm.

• Click on generate mesh and the mesh will be generated on the surfaces as below.

• Create the fixed supports and select the faces as below.

• Insert a joint and set the type as rotation and assign the values for the lever to rotate.
• Check the axis of rotation to avoid issues during the simulation.

• In the analysis settings set the number of steps and other details as below,

CASE-1: Copper Alloy NL

Equivalent Elastic Stress(On the wire alone):

Equivalent Elastic Strain(on the wire alone):

CASE-2: Aluminium Alloy NL

Equivalent Elastic Stress(On the wire alone):

Equivalent Elastic Strain(on the wire alone):

CASE-3: Magnesium Alloy

Equivalent Elastic Stress(On the wire alone):

Equivalent Elastic Strain(on the wire alone):

Results: The results of the 3 non-linear materials are listed below for the wire bending simulation using static structural analysis using Ansys Workbench.

Non-linear Materials	Equivalent Stress (MPa)	Equivalent Strain
Copper Alloy C-1	342.04	0.0031
Aluminium Alloy C-2	312.23	0.0044
Magnesium Alloy C-3	261.45	0.0058

Conclusion: The values of each case are different as the non-linear material applied has different properties, the stress is highly developed in the case of Copper Alloy Non-linear material and least in Magnesium Alloy Non-Linear material.