Week 4 -Wire Bending Challenge

Objective:

For this challenge, we will have to perform an analysis to simulate the bending of a wire in ANSYS. we will have to use Copper Alloy (Non Linear), Aluminium Alloy (Non Linear) and Magnesium Alloy ( Non Linear) for the wire alone. You need to find out the Equivalent stress and Equivalent strain on the wire alone.

Procedure:

• open ansys
• select static structural<select engineering data and add copper alloy,alluminium alloy,magnesium alloy to the library

• rename parts in geometry as wheel,wire,lever
• assign material of wire as copper for case 1
• go to connections<contacts<delete default contacts which are un necessary then flip the contacts<click on rename based on definition<select wheel surfaces except groove<apply
• select both contacts and type as frictional with coefficient of friction is 0.2 and formulation is augmented lagrange<normal stiffnes as factor with 0.1,update status each iteration<interface treatment is add offset ramped effects

• Go to mesh select method as tetrahedral<sizing select contact faces with element size of 2.2mm

• create new coordinate system<select offsetx,offsetz values as 3mm,-3mm respectively
• mesh <insert<sizing<select wire<apply<element type as sphere of influence<sphere centre=select coordinate system<sphere radius=7mm with element size 0.8mm<generate mesh

• go to analysis settings<no of steps 8<select 1st step<solver type=direct<weak springs=programme controlled<large deflection is on<auto time stepping is on<defined by time<initial time step=0.1<minimum time step=1e-2<maximum time step=0.2

• select 2 to 8 steps<auto time step=on<defined by=time<carry over time step=on<minimum time step<1e-2<maximum time step=0.2<large deflection=on
• go to static structuiral<insert<fixed support<select wheel inner dia

• go to connections<insert<joint<type=revolute<select inside dia of lever<coordinate system<apply

• go to static structuiral<insert<joint load<joint=revolute joint<DOF=ROTATIONZ<MAGNITUDE TABULAR

• go to mesh<quality<smoothening=low<go to solution<insert<total deformation<strain<stress<wire stress<wire strain<solve

Results:

case:1

Equivalent stress :

Equivalent strain:

case:2

Equivalent stress :

Equivalent strain:

case:3

Equivalent stress :

Equivalent strain:

Rsult comparrison:

	Equivalent stress(Mpa)	Equivalent strain
case1(alluminium)	312.07	0.0044118
case2(copper)	321.95	0.0029492
case3(Magnesium)	233.93	0.0053604

Discussion:

maximum amount of stress developed in copper wire followed by alluminium and magnisium