STRUCTURAL ANALYSIS VERIFICATION OF WELD JOINTS
STRUCTURAL ANALYSIS VERIFICATION OF WELD JOINTS
Objective :
The objective of this project is to simulate structural analysis verification of weld joints with three different types of welding using three different weld materials.
Case 1. Stainless Steel: In this case, the material of the plates must also be the same. Use Stainless steel for both weldments and plates. No need to add flux to the weldments.
Case 2. Aluminium Alloy:The material to be chosen for this case is Aluminium alloy(high strength, wrought). [Plate material to be used is stainless steel]
Case 3.Bronze: In order to simulate \"Brazing\", you should be using bronze as the weld material. Assign Stainless Steel to both plates and Copper to the \"Ribs\".
CAD model
SIMULATION SETUP :
The pre-processing steps are followed for all the cases.
CONTACT SETUP :
Frictional Contact has been set between big palte,small plate,rib-1 and rib-2 with frictional coeffiecient of 0.2 which would be interacting at the interface which has been set to add offset,no ramping as shown below.The formulation of contact is set as Augmented Lagrange.
Fritional contact
MESHING :
CAD Model is meshed with an element size of 7 mm to keep the elements/nodes 32k which is the maximum limit for the academic version of the software which resulted in 25092 nodes and 4118 elements are shown below.
Meshed model
BOUNDARY CONDITIONS :
The fixed support is assigned at the holes in the cad model and force of 15000N is assigned at the rectangular hole in the small plate.
Boundary conditions
SIMULATION RESULTS :
Case-1 :
In this case the stainless steel is assigned to welding materials and the rest.
Directional deformation :
Equivalent Elastic Strain :
Equivalent Stress :
Stress (Weld Joints) :
Case-2 :
The welding material is aluminium alloy (high strength, wrought) and the rest are stainless steel.
Directional Deformation :
Equivalent Elastic Strain :
Equivalent Stress :
Stress (weld joints) :
Case-3 :
The material assigned to plates is stainless steel, ribs of copper and welding material is bronze.
Directional Deformation :
Equvalent Elastic Strain :
Equivalent stress :
stress (weld joints) :
The below figure shows the weld joint that experiences the highest equivalent stress.
ANIMATION LINK :
https://drive.google.com/drive/folders/19P515QVbqrVSK8kLCkArIWUxaqFbQUwS
CONCLUSION :
As per the above table the deformation is high in cast bronze and least in stainless steel i.e 0.41299 and 0.36582 respectively.The Equivalent elastic strain is max in stainless stell of 7.8264e-4 and min in cast bronze of 1.0479e-3.The max stress on weld joints is in stainless steel and min is in aluminium alloy i.e., 280.29 and 234.24 respectively.From all the observations the max stress is occured in weld joints where the load is applied.