Week 4 -Wire Bending Challenge

OBJECTIVE:

• Set up the model for wire bending with different materials
• Compare the results with different cases

Steps:

Import the material

• First open the ansys workbench and import the materials
• Go to Engineering data>Engineering Data sources>Genral Non linear materials
• Select Copper alloy, Magnesium Alloy, Aluminum Alloy non linear materials

Import the Geometry:-

• Import the geometry from saved location
• Open the model in space claim and check for any abnormality
• In space claim we can edit the model to our requirement

Set up the model:-

• Open the Mechanical workbench for model set up
• Initially rename the geometry for convinience
• Assign the wire material as copper alloy,Magnesium alloy, Aluminium Alloy  for case 1,2,3 respectievly
• Delete the default contact between wheel , wire and lever
• Now create connection between Wire-Lever and Lever-Wire
  

Create Joint:-

• Define Joint load for lever like shown below
  

Mesh:-

• Mesh all the bodies with element type tetrahedron
• Perform face sizing of 2.2mm for contacting faces
• The fillet in the wheel , where more amount of stress might take place, so it is better to refine mesh
• Create a new co-ordinate system near filleted region,
• Using the newly created cordinate system, create sizing of element size 0.8mm
  Type=Sphere of influnce
  Sphere centre=Newly created cordinate system
  Sphere radius=7mm

Analysis Setting:-

• Number of steps=8
• For step 1
  Solver type=Direct
  Weak springs=Program controlled
  Large deflection =ON
  Auto time-stepping=ON
  Initial time step=0.1
  Minimum Time step=0.01
  Maximum Time step= 0.2
• For step 2 to 8
  Auto time stepping=ON
  Defined by=Time
  Carryover time step=ON
  Minimum time step=0.01
  Maximum time step=1

Define Load:-

• Define a fixed support for the Wheel
• Define Fixed support to the end of wire
• Define Revolute joint with DOF Z
  Magnitude=tabular data
  

Output Request:-

• Note down the results for Equivalent Stress, Equivalent Strain and total Deformation
• Note down the results for all the three cases

Results:

Copper Alloy:-

• Equivalent Stress
  
• Equivalent Strain
  
• Total Deformation
  

Aluminum Alloy:-

• Equivalent Stress
  
• Equivalent Strain
  
• Total Deformation
  

Magnesium Alloy:-

• Equivalent Stress
  
• Equivalent Strain
  
• Total Deformation
  

• Material	Equivalent Stress(Mpa)	Equivalent Strain(mm/mm)	Total Deformation(mm)
  Copper Alloy	334.5	0.0030804	262.64
  Magnesium Alloy	257.92	0.0057459	262.64
  Aluminium Alloy	324.41	0.00458577	262.64

CONCLUSION:

• We can see the results from above table, the highest stress generated in all the cases are at wire
• The highest stress generated in copper alloy
• The lowest strain generated in copper alloy
• Total deformation is same in all the case