Finite Element Analysis of Weld Joints using Ansys Workbench
Objective: Compare the Finite Element Analysis results obtained by using 3 different materials for Welded Joints Setup and write a detailed report explaining the results obtained.
Case Setup and Execution:
Model:
Boundary Conditions:
Contacts: Frictional type of Contacts has been applied to BIG & SMALL PLATE, BIG PLATE & RIB-1, BIG PLATE & RIB-2, SMALL PLATE & RIB-1, SMALL PLATE & RIB-2 and bonded type for all other contacts as shown below.
Mesh: Size of element- 17mm.
Body Sizing: Size of element- 5.5mm (Big & Small Plate)
Analysis Settings:
Fixed Support:Fixed Suport has been applied to the circular holes on the big plate as shown below.
Force: Force of 15000N has been applied in +Y direction on the rectangular hole of small plate as shown below.
Case-1:
Plate Material: Stainless Steel
Rib Material: Stainless Steel
Weld Material: Stainless Steel
Results:
Equivalent Elastic Strain:
Directional Deformation:
Equivalent Stress (Weld Joints):
Case-2:
Plate Material: Stainless Steel
Rib Material: Stainless Steel
Weld Material: Aluminium Alloy (high strength, wrought)
Results:
Equivalent Elastic Strain:
Directional Deformation:
Equivalent Stress (Weld Joints):
Case-3:
Plate Material: Stainless Steel
Rib Material: Copper Alloy
Weld Material: Cast Bronze
Results:
Equivalent Elastic Strain:
Directional Deformation:
Equivalent Stress (Weld Joints):
Two weld joints have experienced the highest equivalent stress in all cases as shown below.
Results Comparison & Conclusion:
| Deformation | Equivalent Elastic Strain | Equivalent Stress (Weld Joints) | ||||
| mm | * | Mpa | ||||
| Min. | Max. | Min. | Max. | Min. | Max. | |
| CASE-1 | -0.025794 | 0.39075 | 7.52E-07 | 0.0020827 | 3.4574 | 227.97 |
| CASE-2 | -0.023931 | 0.40721 | 7.17E-07 | 0.0030375 | 2.8265 | 224.09 |
| CASE-3 | -0.016611 | 0.45657 | 9.12E-07 | 0.0030721 | 2.5617 | 245.7 |
- Total deformation, Equivalent Stress of weld joints is higher in Case-3.
- Equivalent Elastic Strain is higher in Case-3 when compared over all but negligible as compared with Case-2.
- As the small plate material in all cases is stainless steel where max. deformation observed, the difference in deformation is because of the weld material and rib material in Case-3.
- In Case-3, Copper and Stainless Steel can be welded but it's extremely difficult and offers very little strength, because stainless steel is not fully soluble with copper and both have different melting points.