Week 4 -Wire Bending Challenge

WIRE BENDING CHALLENGE

Objective: -

i. We will have to perform an analysis to simulate the bending of a wire in ANSYS. We will assign non linear materials for the wire

• Copper Alloy NL

Aluminium Alloy NL

• Magnesium Alloy NL

ii. Find out the equivalent stress and equivalent strain on the wire.

Procedure:

• Import the geometry and assign copper alloy non-linear material to the wire. We will follow the same procedure to assign different materials to the wire for analysis.

Connections

Friction contacts are provided between the lever-wire and Wheel-wire with a frictional coefficient set to 0.2.Contact and target body assignment must be taken care of while providing contacts.

Revolute Joint

Revolute Joint is provided to the lever that will perform the bending of the wire.The rotation values can be traced from the below fig

MESHING

The meshing of the model is done using tetrahedron elements.Wire, wheel and lever has importance regions that will come in contact with each other while moving We have to mesh these areas with an element size of 2.2mm and also another face sizing between the wire and the wheel with an element size of 0.8 mm using sphere of influence.

ANALYSIS SETTINGS

An analysis is performed using 8 steps with Auto Time stepping ON and the type of solver we use is direct which is one of the many methods to solve simultaneous equations and with additional settings provided as shown below..

BOUNDARY CONDITIONS:

Fixed support is applied to the wheel and at the tip of the wire to restrict the movement of the wire during the simulation which otherwise

RESULTS

COPPER ALLOY

ALLUMINIUM ALLOY

MAGNESIUM ALLOY

STRESS

STRAIN

Conclusion: -

1. To refine meshing at an area which is of importance using the sphere of influence.

2. Setting fixed supports and joint load conditions.

3. Setting up Analysis setting for Non-Linear Analysis and time-step for simulation.