Week 4 -Wire Bending Challenge

AIM: To perform the wire bending simulation.

PROCEDURE:

• So first we will import the model in ANSYS workbench. After that we will select the material for the WIRE.
• The material we are choosing are Copper Alloy (Non Linear), Aluminium Alloy (Non Linear) and Magnesium Alloy (Non Linear.
• The actual component is shown below:

• Now after that we will assign the contacts to the Wire and lever, Wire and wheel as shown below:

• And change the contact settings as shown:

• After this we will mesh the components. So first select the method as Tetreahedrons for the meshing by selecting all the components.
• Then select the faces as shown and refined the mesh size as 2.2mm.

• After this we will create a revolute joint on the lever.

• Now since the area where the wire is going to bend we have refine the mesh at that perticular area. So for that create a new co-ordinate system.
• Select the area as shown below and create a new co-ordinate system. After that select X and Z offset and enter the value as 3mm and -3 mm respectively as shown:

• After that create a new mesh sizing slect the rod as geometry and change the setting as shown:

• Change the mesh smoothing as low. And generate the mesh.

• Next is to change the Analysis setting, so we are using 8 steps of this. So for the 1st step the setting as below:

• And for step 2 to 8 the setting as shown:

• Next is to fixed the wheel so create a fixed support on the wheel:

• And add the joint load with rotation along Z axis.

• After that add the results we want to see and solve the solution.

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

Sr No.	MATERIAL	Equivalent stress (MPa)	Equivalent strain
1	Copper Alloy	341.2	0.00317
2	Aluminium Alloy	319.87	0.00452
3	Magnesium Alloy	258.76	0.00577

CONCLUSION:

• As we can see that the equivalent stress and strain changes as we change the material.
• Here we can observed that the as the equivalent stress is decreasing the equivalent strain is increasing little bit.