Weak-Excitation Steel Rope MFL Simulation as steel wire rope is 6x37 wires

Job ID: 39818275

Budget: ₹1,500 – ₹12,500 INR

I need a full COMSOL Multiphysics model that reproduces weak-magnetic-excitation testing on a multilayer steel wire rope and lets me quantify magnetic flux leakage (MFL) caused by broken wires. The emphasis is on measuring magnetic flux density in and around the rope, then isolating and visualising the leakage field that appears at each simulated fracture.

Scope of the study
• Build or import a realistic 3-D rope geometry (strands and core) with one or more intentionally broken wires.
• Apply a low-level DC (or quasi-static) excitation so the system sits in the weak-magnetisation regime—no saturation.
• Solve with the Magnetic Fields interface (AC/DC Module) and extract: magnetic field strength (H), flux density (B), local magnetisation, remanent flux density, and especially the spatial MFL signature around the defects.
• Provide plots, numerical probes, and exportable data for every parameter above, plus a short note on how rope diameter, break location, and excitation current alter the leakage pattern.

Deliverables
1. The COMSOL .mph file, ready to re-run.
2. A brief report (or annotated PDF) explaining geometry set-up, material properties, boundary conditions, mesh strategy, solver settings, and where to find each result node.
3. Screenshots or figures highlighting the MFL envelope for at least one intact and one broken-wire scenario.

Acceptance criteria
– Simulation runs without errors on COMSOL 6.x using standard AC/DC licences.
– Result plots clearly distinguish intact from broken conditions through measurable leakage amplitude.
– All requested field quantities (B, H, magnetisation, remanence) are accessible as datasets or exported CSV.

I am not analysing stress or corrosion; the work is strictly magnetic. If any simplifications are necessary—periodic symmetry, reduced strand count, etc.—please mention them so I can judge the trade-offs.