Week 4 -Wire Bending Challenge

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

Software: Ansys 2021 R1

Summary

Objective

Procedure for setup

Results

Comparison

Conclusion

Objective:

To simulate the bending of a wire for 3 different materials

To find out the Equivalent stress and Equivalent strain on the wire alone

To compare the results

Introduction:

This wire bending test is a method of testing materials for knowing about their bending strength and other important properties. This is basically conducted by fixing the wire in a wheel and bending the wire by the help of a lever which will rotate

Open ANSYS>>Drag and drop static structural model in the project schematic window.

Go to the engineering data to choose the materials (Aluminium Alloy 1199, Copper Alloy NL and Magnesium Alloy NL

Go to the model tab

Rename the different as required

Go to connection >> contacts

Set the contacts as follows

Go to tab for the meshing:

For the meshing choose the values as follows:

The following analysis settings are defined for the simulation.

The following joints are defined:

Go to solution tab and insert equivalent stress, directional deformation, equivalent elastic strain.

RESULTS:

Case 1 : Copper Alloy (Non Linear)

Equivalent stress

Equivalent strain

Case 2 : Aluminium Alloy (Non Linear)

Equivalent stress

Equivalent strain

Case 3 : Magnesium Alloy ( Non Linear)

Equivalent stress

Equivalent strain

Comparison

Materials	Maximum Equivalent Stress (MPa)	Maximum Equivalent elastic strain (mm)
Copper Alloy NL	337.81	0.0030875
Aluminium Alloy NL	303.65	0.0043391
Magnesium Alloy NL	224.76	0.0056519

Conclusion:

Trough this analysis, we can se that the stress is higher when using copper alloy (NL) and lower in the case of magnesium alloy whereas the equivalent elastic strain is lower when using copper alloy and higher in the case of magnesium alloy.