Week 3 Verification of Weld Joints
objective: To set up the given simulation to test to characteristic of the weld and how they affect the deformation of the metal plates by changing the material and observing the behaviour
procedure: setting up the simulation, first we need to import all required material cards such as stainless steel, aluminium alloy(high strength, wrought) and cast bronze. The above material can be found in the ganta material liberary
stainless steel
aluminium alloy(high strength, wrought)
cast bronze
importing geometry: Next we import the geometry which is the creo cad file of the plate step up which has been provided.
material definition :
The material stainless steel is assigned to all the components including plates and weld for the first case then we will open ansys mechanical to set up the rest of the simulation.
To set up the contact we go to connection-->contacts and select rename based on definition.
for the last five contact as they are between the plates we will change the type to frictional with the coefficient of friction as 0.2
type=frictional
coefficient of friction=0.2
The rest of the contact as they consist of the weld elements we will let them be as bonded type
next a mesh is generated.
we use body-sizing to generate mesh size for different component as shown
for the two plates, we use a mesh size of 7mm as shown
for the two plates, we use a mesh size of 9mm as shown above. this concludes the mesh generation.
creation of loads
Next we define the physics of the problem we will make the big plate fixed using the holes on its surface using fixed support option as shown
Then we assign a force the perpendicular plate along the rectangular slit as shown. A force of 15000N is applied in the downward direction to pull it in a perpendicular direction to the big plate.
setting up the analysis setting: Next the analysis setting are selected as shown below. the value of number of steps automatic time-stepping are kept as default large deflection is switched ON
Output parameter
running the simulation
Next we run the simulation. The simulation runs rather quickly in about 23.6 sec
post processing
we will evaluate the result for the different material assignment for the weld parts with plates being in stainless steel.
stainless steel
aluminium alloy
cast bronze
equivalent stress:
1) case
maximum stress of 337.96 Mpa is experienced
2) case
maximum stress of 343.24 Mpa is experienced
3) case
A maximum stress of 342.66 Mpa is experienced
equivalent elastic stress
1) case
Maximum strain of 0.18% is experienced
2) case
Maximum strain of 0.35% is experienced
3) case
Maximum strain of 0.33% is experienced
directional deformation
1) case
A directional deformation of 0.335mm is experienced by the small plate in the force direction
2) case
A directional deformation of 0.35mm is experienced by the small plate in the force direction
3) case
A directional deformation of 0.348mm is experienced by the small plate in the force direction
factor of safety :
case 1)
A minimum of 0.61 FOS occurs.
case 2)
A minimum of 0.6 FOS occurs.
case 3)
A minimum of 0.55 FOS occurs.
Maximum weld stress:
The stresses being experienced by the weld made of different material are explained below according to material case study.
case 1)
The maximum stress being experienced by the weld element is 311.18 Mpa as shown above
case 2)
The maximum stress being experienced by the weld element is 256.54 Mpa as shown above
case 3)
The maximum stress being experienced by the weld element is 260.38 Mpa as shown above
The consolidated result have been given below in table format:
equivalent stress equivalent strain directional deformation Fos
stainless steel 337.96 Mpa 0.18% 0.335mm 0.61
aluminium alloy 343.24 Mpa 0.35% 0.35mm 0.6
cast bronze 342.66 Mpa 0.33% 0.348mm 0.55
conclusion:
Hence the simulation have been successfully conducted with the different weld material and the desired output has been obtained .