Week 3 Verification of Weld Joints

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 the 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

PRODECURE

• Create Static structural analysis and in engineering data select the material stainless steel ,Aluminum alloy and Bronze
• Stainless Steel

• Aluminium Alloy

• Bronze

• Import the geometry and check in spaceclaim for any irregularties.
• 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.Mpa

Total Deformation Max - 0.34278mm

Equivalent Strain Max - 0.002135 mm/mm

Equivalent Stress on Weld joints Max - 310.6 Mpa

Case 2 Aluminum Alloy

Equivalent Stress Max - 391.07 Mpa

Total Deformation Max - 0.35732mm

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

Material Equivalent Stress max Mpa Total deformation max mm Equivalent Strain Max Equivalent stress on weld joints

Stainless Steel 385.35 0.34278 0.002135 310.6

Aluminum alloy 391.07 0.35732 0.0035327 260.45

Bronze 396.21 0.38397 0.0033794 269.62

• 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.