Wire bending process

Hints
Material assigning & Contacts
Assign copper alloy nl to the wire

Contact regions

Establish 2 contact regions

Frictional -wire to lever

Frictional - wheel to wire

Meshing options
Select all bodies and apply Tetrahedrons meshing method

Apply face sizing for wire, the faces of slot and wheel face as shown(2.2mm)
Create coordinate system near fillet of slot

Offset x and z by 3 and -3 mm respectively

Insert another face sizing
Type :sphere of influence

Size:0.8mm

Sphere center :new coordinate system

Sphere radius:7mm
Rotational joint
Create a rotational joint by selecting the face of larger hole
Tabular detail for joint load
0 0

1 -20

2 -40

3 -60

4 -80

5 -100

6 -120

7 -140

8 -160