Week 3 Verification of Weld Joints

Objective: To simulate Welding Joint in ANSYS using three different materials(stainless steel , Copper , Bronze , Aluminum)

Case Setup & Execution:

1. Open Workbench & Setup static structural.
2. Import Geometry from the required folder.
3. Click on Engineering data & select appropriate material such as Stainless steel, Bronze & Copper.
4. Update the model and click edit. Rename the parts. After that select the material required for various joints.
5. Click on contacts and select Rename based on definition. It will show up all the Contacts.
6. Select the 5 pairs leaving all other Weld joint and provide a frictional Contact with coefficient of friction as 0.2.
7. Now in mesh we have provided a mesh size of 4mm to Small, Big plate. To other parts a mesh size of 7mm is considered. After generating the mesh was fine grid and good looking to proceed further.
8. In analysis setting click on Large Deflection.
9. Now moving to final part static structural. Add fixed support and select four holes of big plate as they are been bolted to the wall. Later insert force load and provide a load of 15000N in ‘y’ direction.
10. Final step is to add all the results required such as Directional Deformation, Stress, Strain, Pressure and Safety Factor.

Results:

Sr No	Max Directional Deformation along ‘y’ axis (mm)	Max Equivalent Strain	Max Stress in Weld Joints(Mpa)	Pressure in Contact joints(Mpa)
Case 1	0.3599	0.002163	302.4	62.21
Case 2	0.4738	0.003585	264.6	66.02
Case 3	0.4278	0.003185	254.8	63.22

Case 1:

In this we have selected Stainless steel as material for Weldments, Plates & Ribs. Mesh of 4mm to plates & 7mm to other parts has been provided to generate fine mesh and obtain most accurate results. Maximum stress generated is 390.68 along with directional deformation of 0.3592. Strain generated is 0.002163.Stress in Weld joints is 302.4 Mpa. Pressure developed is 62.21Mpa.A safety Factor of 15 is shown in results.

Case 2:

In this we have selected Stainless steel as material for Plates & Aluminum alloy for Ribs, Weldments. Mesh of 4mm to plates & 7mm to other parts has been provided to generate fine mesh and obtain most accurate results. Maximum stress generated is 413.16 along with directional deformation of 04738. Strain generated is 0.003585.Stress in Weld joints is 264.6 Mpa. Pressure developed is 66.023Mpa.A safety Factor of 15 is shown in results.

Case 3:

In this we have selected Bronze as Weld material, Stainless steel as plates & Copper for ribs. Mesh of 4mm to plates & 7mm to other parts has been provided to generate fine mesh and obtain most accurate results. Maximum stress generated is 406.3Mpa along with directional deformation of 0.4278mm. Strain generated is 0.0031853.Stress in Weld joints is 254.82 Mpa. Pressure developed is 63.22Mpa.A safety Factor of 15 is shown in results.

Results & Solution:

From the above attached table and results generated after simulation it’s been observed that equivalent stress is maximum in weld joints where the material is stainless steel. Also directional deformation is maximum in case3 as the material chosen are steel, Copper & Bronze. This show that Bronze as Weldments allows the maximum deformation along the ‘y’ direction compared to other two materials. Equivalent strain is maximum in Case2 with a maximum value of 0.003585.Stress stool is considered as 15 for all the three cases.

Note - Images are attached for reference with code name results_case1/case2/case3. Animated video is also attached. Simulation is attached in required file as mentioned.