Verification of Weld Joints using Ansys

Objective - Simulate Structural analysis of weld joints using three different weld materials and compare the Directional Deformation, equivalent stress and equivalent strain.

• 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 theweld material. Assign Stainless Steel to both plates and Copper to the "Ribs".

Procedure -

• Create Static structural analysis and in engineering data select the material Stainless Steel, Aluminium Alloy and Bronze.
• Stainless Steel.

• Aluminium Alloy.

• Bronze.

• Import the geometry and check in SpaceClaim for any irregularities.
• Then open Ansys mechanical and rename the geometry as Bigplate, Smallplate, Rib1 and Rib2 then assign the material according to the cases.

• Contacts - there are 5 contacts created in the whole setup with frictional type and friction coefficient of 0.2.
• Between Bigplate and Smallplate.
• Between Bigplate and Rib1.
• Between Bigplate and Rib2.
• Between Smallplate and Rib1.
• Between Smallplate and Rib2.

• Mesh - Mesh the model with using body size option Bigplate and Smallplate is mesh in element size of 4mm.

• Fixed Support - All the holes of Bigplate are fixed.

• Load - Force of 15000N is applied at the rectangular hole of Smallplate.

• Then the last step is run the simulation and results obtained.

Result -

Case 1 Stainless Steel

Equivalent Stress Max - 385.35 Mpa

Total Deformation Max - 0.34278 mm

Equivalent Strain Max - 0.002135 mm/mm

Equivalent Stress on weld joints Max - 310.6 Mpa

Case 2 Aluminium Alloy

Equivalent Stress Max - 391.07 Mpa

Total Deformation Max - 0.35732 mm

Equivalent Strain Max - 0.0035327 mm/mm

Equivalent Stress on weld joints Max - 260.45 Mpa

Case 3 Bronze

Equivalent Stress Max - 396.21 Mpa

Total Deformation Max - 0.38397 mm

Equivalent Strain Max - 0.0033794 mm/mm

Equivalent Stress on weld joints Max - 269.92 Mpa

Conclusion -

• Deformation is maximum in Bronze.
• Equivalent Stress is highest in Bronze.
• Equivalent Strain is highest in Aluminium alloy.
• Equivalent Stress on weld joints is maximum in Stainless Steel.

Google drive link - https://drive.google.com/file/d/1E7lsMPiUxnzQ0eZ5-LTBoOXHOuhvsot0/view?usp=sharing