Week 3 Verification of Weld Joints

Aim-

To simulate three different types of welding using three different weld materials by structural analysis.

Objective-

Weld Material used:

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".

Run the simulation for a load of 15000N that is to be applied at the rectangular hole in the small plate, or each case, find out the Directional Deformation and equivalent strain experienced by the setup. Identify the weld joint that experiences the highest equivalent stress in each case and compare the results for all three cases.

Welding Theory-

Welding is a fabrication process whereby two or more parts are fused together by means of heat, pressure or both forming a join as the parts cool. Welding is usually used on metals and thermoplastics but can also be used on wood. The completed welded joint may be referred to as a weldment.

Some materials require the use of specific processes and techniques. A number are considered 'unweldable,' a term not usually found in dictionaries but useful and descriptive in engineering.

The parts that are joined are known as a parent material. The material added to help form the join is called filler or consumable. The form of these materials may see them referred to as parent plate or pipe, filler wire, consumable electrode (for arc welding), etc.

Consumables are usually chosen to be similar in composition to the parent material, thus forming a homogenous weld, but there are occasions, such as when welding brittle cast irons, when a filler with a very different composition and, therefore, properties is used. These welds are called heterogeneous.

The completed welded joint may be referred to as a weldment.

Where It is Used?

Welding processes are commonly used across a range of industries including aerospace, automotive, energy and construction amongst others. Used to join metals, thermoplastics or wood for a variety of applications, it is also used to create artwork by a growing community of artists.

Procedure-

• We have to first start as new project in the ansys workbench and select the proper material for the weld joint plate.
• Here material has been specified in the project so we will select materials as per case.

Case-1-Stainless Steel

Case-2-Stainless-Steel & Alluminium Alloy-

Case-3- Bronze Cast & Copper Cast

• Now we have to import the model for that right click on the geometry tab and hit import>>then select the file from saved location and hit ok.

• We have to now remane the plate parts name and the proceed further for connections.

Connections-

• Now we have to open mechanical model and the need to specify connections to railwheel track.
• We have to right click on the connection and then click on rename based on defination.
• For All 4 plates there is frictional contact present in between so we select from tree all connections in between plates and give frictional contact.

• Rest of the connections going to remain bonded.

Mesh-

• Go to mesh then right click and the click on insert and select sizing.
• select size of 7mm as mesh size for big plate and small plate.
• For rest we will keep element size as default.

Analysis setting-

• Go to analysis setting and set large deflection ON and refer below setting for 1st step.

• Now we have to apply fixed support to the bolted joint which is going to be circular holes.

• we have to now apply force of 15000N in Y-direction in Rectangular hole.

Solution-

• Here we have to define directional deformation, to do so right click solution>>insert>>deformation>>directional.
• Here we have to select Y-axis for force directional.

• Now for strain right click on the solution>>insert>>strains>>equivalent elastic (von-Mises).
• Now for stress right click on the solution>>insert>>stresses>>equivalent (von-Mises). for plates and seperately for weld joints.
• Right click on solution and hit solve.

Result-

1. Directional Deformation-

Case-1-Stainless Steel-

Case-2-Stainless Steel & Alluminium Alloy-

Case-3- Stainless Steel, Bronze Cast & Copper Cast-

2. Equivalent Elastic Strain-

Case-1-Stainless Steel-

Case-2-Stainless Steel & Alluminium Alloy-

Case-3- Stainless Steel, Bronze Cast & Copper Cast-

3. Equivalent Stress with only plates in consideration-

Case-1-Stainless Steel-

Case-2-Stainless Steel & Alluminium Alloy-

Case-3- Stainless Steel, Bronze Cast & Copper Cast-

4. Equivalent Stress with only weld joints in consideration-

Case-1-Stainless Steel-

Case-2-Stainless Steel & Alluminium Alloy-

Case-3- Stainless Steel, Bronze Cast & Copper Cast-

Result Comparision-

Cases	Directional Deformation (mm)		Equivalent Elastic Strain		Equivalent stress for plates only (MPa)		Equivalent stress for Welds only (MPa)
	Min.	Max.	Min.	Max.	Min.	Max.	Min.	Max.
Case-1	-0.03313	0.35136	8.31E-07	0.001812	0.1577	337.68	1.21	302.43
Case-2	-0.03233	0.36543	9.42E-07	0.003414	0.1572	342.3	1.24	251.76
Case-3	-0.02795	0.39507	6.034E-07	0.003288	0.07917	347.19	1.39	262.72

So from above table we can say that directional deformation is highest in case 3 and lowest in case 1, this is due to lower strength (yield) which causes high stress near plates which may lead to failure of joints.

Similarly strain is highest in case 2 and lowest in case 1, highest strain is due to alluminium has low modulus of elasticity which leads to high strain.

Stress is highest for both condition in case 1(approx.) this is due to presence of steel in whole part.

Aminated files-

Case-1

Directional Deformation-

Equivalent Elastic Strain-

Equivalent Stress with only plates in consideration-

Equivalent Stress with only weld joints in consideration-

Case-2

Directional Deformation-

Equivalent Elastic Strain-

Equivalent Stress with only plates in consideration-

Equivalent Stress with only weld joints in consideration-

Case-3

Directional Deformation-

Equivalent Elastic Strain-

Equivalent Stress with only plates in consideration-

Equivalent Stress with only weld joints in consideration-

Conclusion-

We have successfully performed the structural analysis on weld joint plate with different material cases, from which we can say that bronze has best weldability but strength is poor in brazing joints.

Strength is high in both alluminum and in steel but after welding steel become bulky and aluminum steel remains light in weight.

So dpeneding upon the requirement we can use type of material for metal to metal joing process.