Week 3 Verification of Weld Joints

Aim of the Analysis:

Run the below simulation cases with load of 15000 N applied at the rectangular hole in the small plate.

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".

Objective:

The Verification of weld joints analysis to find Directional Deformation, Equivalent Strain and Equivalent Stress in the Rectangular hole based on the diffferent weld materials.

with this use of different welding material we will have different strength of the part and failure analysis is important due to which this analysis will provide better idea on the better weld material to be used for the applied load of 15000 N in any application.

Analysis Parts used & Weld Material properties Details:

Details	Structural Steel	Stainless Steel	Aluminium Alloy	Bronze	Copper(ribs)
Density Kg/m3	7850	7750	2770	8810	8942
Tensile Yield Strength (MPa)	250	207	363	144	250.8
Tensile Ultimate Strength (MPa)	460	586	449	267	343.2
Possion Ratio	0.3	0.3	0.34	0.345	0.345
Young's Modulus(MPa)	2e+05	1.93e+05	73800	80000	1.26e+05

Connection Details:

1. Baseplate to Sideplate:

2. Baseplate too Gusset 1:

3. Baseplate to Gusset 2:

4. Sideplate to Gusset 1:

5. Sideplate to Gusset 2:

Body Mesh Sizing Details:

With Element size of 7 mm for the body in all cases for all the weld material with below Element metrics details:

Analysis Setting & Output Control Details:

With Large deflection is switched on, Stress , Strain for the output controls.

Fixed Support details:

Force Details:

Load applied at the rectangular hole

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.

The results are provided below for this case :

Equivalent Stress (MPa):

Directional Deformation(mm):

Equivalent Elastic Strain:

Weld Material Equivalent Stress details:

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]

The results are provided below for this case :

Equivalent Stress (MPa):

Directional Deformation(mm):

Equivalent Elastic Strain:

Weld Material Equivalent Stress details:

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".

The results are provided below for this case :

Equivalent Stress (MPa):

Directional Deformation(mm):

Equivalent Elastic Strain:

Weld Material Equivalent Stress details:

Conclusion:

Weld Material	Equivalent Stress (Mpa)		Directional Deformation(mm)		Equivalent Elastic Strain		Stress in weld material(Mpa)
	Maximum	Average	Maximum	Average	Maximum	Average	Maximum	Average
Stainless Steel	342.4	23.3	0.36	3.38E-02	7.84E-04	9.19E-05	282.96	37.32
Aluminium Alloy	347	22.7	0.38	3.55E-02	7.69E-04	9.06E-05	235.04	30.73
Bronze(Copper Ribs)	352.9	22.6	0.42	4.06E-02	1.15E-03	1.32E-04	247.8	31.06

By comparing Equivalent Stress and Deformation data we can conclude that Bronze (Brazing) with Copper ribs weld material

are weaker compare to Aluminium alloy and Stainless steel.

We need to note that the selection of the weld material basically depends on the application where part will be used. If we generalise

the process like good Welding , Thermal Properties and Strength we can categories the weld material sequence like below:

Stainless Steel > Aluminium Alloy > Bronze should be the order of selection for the weld material in this application.

I have attached Archieve files of the project of all the cases for reference.