Week 3 Verification of Weld Joints
Weld Joints Analysis using Ansys Workbench
Objective: To study and perform analysis on the weld joints using different materials for the welds and compare the results with each other
Weld material used
Case1- stainless steel for all parts
Case2- Aluminium Alloy for weld parts and stainless steel for ribs and plates
Case3- Bronze for weld parts, stainless steel for plates and copper for ribs
Simulation Process:
Input Geometry
The CAD model is imported and viewed in space claim and making Sure there are no errors in the geometry
Material:
The plate, ribs and weld joints all are assigned with material stainless steel
Contacts:
The direct contact between the ribs and plates as a frictional contact with a frictional coefficient of 0.2 since all the plates are flat, the contact and the target can be chosen arbitrarily for all the contacts. Considering the advantages of using Augmented Lagrange to prevent interpenetrations, it is used as a formulation for all frictional contacts.
On the other hand, since all the welded joints have to be fixed to the plates, they are modelled as bonded joints with arbitrarily contact and target program controlled formulation was used for all the weld joints
Mesh
- The Mesh is created such that the stresses converge. Body sizing is used each of the parts appropriately
Analysis setting:
- The analysis is setup for 1 steps. This does not control the time step, but is only an indication of points where boundary changes. The time step is auto controlled by specifying initial ,min and max time step
Boundary conditions
- the overall Boundary Conditions are shown below
- A fixed support is setup at the 5 hole of the Base Plate
- A 15000N Force is applied to the rectangular hole of the sub plate in the Y- direction
Solutions:
All the necessary output variable are selected such as
- Equivalent stress-only weld
- Directional deformation (y-direction)- all bodies
- Equivalent strain
- Stress tool- only weld
- Contact tool
Note- for all three cases the step are same as above we discuss
Case1- stainless steel for all parts
material assigned
Directional Deformation
equivalent strain
weld joint equivalent stress
Case2- Aluminium Alloy for weld parts and stainless steel for ribs and plates
material assigned
Directional Deformation
equivalent strain
weld joint equivalent stress
Case3- Bronze for weld parts, stainless steel for plates and copper for ribs
material assigned
Directional Deformation
equivalent strain
weld joint equivalent stress
Comparing the result
| Weld material | max directional deformation | max Equivalent strain | Max.Equivalent stress in weld |
|
Stainless steel |
0.34159 mm | 335.14 mm | 307.09 MPa |
|
Aluminium alloy |
0.43513 mm | 3.6086e-003 mm | 265.76MPa |
|
Bronze, cast |
0.38704 mm | 3.2828e-003 mm | 262.25 Mpa |
The Equivalent stress of Bronze is also maximum as compared to other two materials and there is no significant difference between them as for Equivalent strain, it is almost same for all the materials
For the Equivalent stress in the welds, Stainless steel has the maximum stress followed by Bronze and Aluminium alloy has the least stress