Week 3 Verification of Weld Joints

Objective:

For a load of 15000N that is to be applied at the rectangular hole in the small plate, 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 the below cases

Case 1 : Weld Material Structural Steel

Case 2: Weld Material Aluminum Alloy

Case 3: Weld Material Bronze

Material Properties:

Case	Material	Youngs Modulus	Yield Strength
01	Structural Steel	200000 Mpa	250 Mpa
02	Aluminum Alloy	69040 Mpa	259.2 Mpa
03	Bronze	107700 Mpa	505 Mpa

Boundary Conditions / Constraints)

Applicable To all Load Cases.

Big Vertical Plate in image is supported on the Holes.

All contacts / connections of Big Plate, Small Plate, Rib plate 1 & 2 have a frictional Coefficient of 0.2.

All weld connections have a bonded contat to their respective plates.

Meshing:

Same for all cases

Mesh Type: Tetrahedron

Mesh Size:

1. Small & Big Plate: 7 mm
2. Support Plate 1 & 2: 5 mm
3. Welds (22 plcs): 3 mm

Loading Conditions:

3 Step Loading - 5000 N, 10000 N & 15000 respectively

Analysis Results & Conclusion:

Case	Weld Material Yield	Step	Load	Stress on Plate (Mpa)	Strain on Plate (%)	Stress on Weld (Mpa)	Strain on Weld (%)	Directional Deformation (mm)
C01	Steel 250 Mpa	1	5000 N	117.55	0.062	93.91	0.047	0.125
		2	10000 N	227.32	0.119	198.28	0.099	0.230
		3	15000 N	334.61	0.176	296.38	0.148	0.328
C02	Aluminum 259.2 Mpa	1	5000 N	119.58	0.063	72.05	0.104	0.130
		2	10000 N	230.87	0.121	145.71	0.211	0.240
		3	15000 N	340.10	0.179	213.57	0.309	0.344
C03	Bronze 505 Mpa	1	5000 N	118.59	0.062	78.82	0.073	0.128
		2	10000 N	229.11	0.120	165.11	0.153	0.235
		3	15000 N	337.36	0.177	244.66	0.227	0.336

Inferences:

1. For a load of 15000 N on the rectangular slot, the stress on the bottom plate is much higher than its yield limit of 250 Mpa. They will fail in the four corners of the rectangular slot. Steel weld at the inner front will also fail.
2. Brazing provides the strongest weld & Steel welding is the weakest weld.
3. Irrespective of the 3 weld materials, the design is safe to handle a load of 10,000 N.
4. The Weld at inner front - experience the highest stress (refer image)