Boundary Conditions and Solver - Non linear Wire Bending Problem


#1

https://www.simscale.com/workbench/?pid=4128842021555474056#tab_1-0

Hello every one,
Above posted link contains my model I have been trying to bend the along the curved surface and to make the free connector( volume on volume geo 0) touch the surface of the G10-2 piece (volume on volume geo 2). I have tried to give remote displacement which I think terribly went wrong since I am very much new to the interface. I request if anyone can provide me with some input.
Thanking you,
Jithin sai sandra .


#2

Hi Jithin (@jsandra)!

I saw that you also had a look at the bending project from the public projects here: Pipe Bending FEA. The @PowerUsers_FEA and me will have a look at the setup and make some adaptions if necessary and get back to you asap!

All the best!

Jousef


#3

Hi @jsandra,
you were actually not that far away. I made a copy and just changed a few things, amongs the most important were:

  • replace the sliding contact between the wire and the roll from a “sliding contact” to a “physical contact” (the sliding contact just allows relative sliding of surfaces normal to their initial surface normals (no update for large deformations nor separation possible)
  • replace the rotation center for the rotating motion to the center of the roll
  • added a sliding constraint to the free end with the wire clamped
  • I computed a new mesh which has a lot less elements in areas where no dense meshing is needed:

This is how the results look like after a 180° turn:

You can check out the project and review all modifications here: https://www.simscale.com/projects/rszoeke/wire_bending/

For the results to be actually realistic, there are still some things to do, like changing the linear elastic material behavior of the wire with an elasto-plastic one.

Best,
Richard


#4

Hello Mr. Richard,
I am really thankful for your contribution. you almost solved it. I will take your advices into consideration, Physical contact didn’t strike to my mind at any time . In the simulation file I see that in constrains for rotating motion you have selected 2 faces. can I know why ? is there any significant reason ?.
Thanking you.


#5

Hello Mr richard,
The results section of your project doesn’t show the bending results which you posted.
thanking you,
Jithin sai Sandra


#6

Hello sir,
Thanks for your contribution and help.
Best,
Jithin sai Sandra


#7

Hi,
I actually chose 8 faces:

They were more or less random, I just selected a few more to not have a high stress concentration on a face due to the constraint. The correct assignment depend on how this application works in reality. But I guess it does not really matter if you are interested only into the bending of the wire.

To see the deformed shape in the post-processure you would need to add a “Warp by vector” filter.
I guess you might want to watch this webinar on how to use the post-processor: Online Post-Processing with SimScale

Best,
Richard