Week 3 Verification of Weld Joints

objective:Simulate three different types of welding using three different weld materials and then compare the results obtained.

procedure:1.first import the given geometry and then select the material as per given in the 3 cases.

2.create the new material for the bronze cast and the aluminium alloy using the option engineering data with the given properties given below.

3.Edit the model in the mechanical by defining the contacts based on the defination and rename the plates as big and small and the ribs as the 1 and 2 .

4.for the case1 select the material as the structural steel for the component including the welding joints,plates and the ribs.

5.For the case2 select the material as the structural steel for the plate material and the aluminium for the weld assembly and the joints and ribs.

6. For the case3 select the material as the bronze cast for the weld assembly and joints structural steel for the plates and the copper material for the ribs.

7.create the frictional contactas for the plates ,weld assembly ,and the ribs with the frictional coefficient of 0.2.

8.create the mesh by mesh sizing of about the 7mm for the plates and the remaining as the 5mm.

9.create the fixed support for the holes region in the bottom plate and then apply the force of about the 15000N in the direction of the y.

10.In the solution option add the equivalent stress , elastic strain vonmises,directional deformation,stress tool safety factor and the contact pressure and then click on the solve after the simulation is completed then compare the results.

case1:Material used:stainless steel

fig shows the equivalent stress of min of 0.15753mpa and the max of 344.38mpa .

fig shows the directional deformation in y direction of min -0.024094mm and max of the 0.37723mm.

fig shows the equivalent elastic strain for both the ribs of min of 1.863e-05 and max of 0.00039643mm/mm.

fig shows the equivalent stress for the weld joints with the min of 2.9215mpa  and the max of the 283.14mpa.

fig shows the max and min safety factor of min 0.73204 and max of 15.

fig shows the contact status as over constrained,far,sliding,sticking.

fig shows the min and max pressure of min0mpa  and the max of the 34.805mpa. 

fig shows the min force of 2.5529N and max force of 2456.7N 

CASE2: Aluminium Alloy:The material to be chosen for this case is Aluminium alloy(high strength, wrought). [Plate material to be used is stainless steel]

fig shows the equivalent stress of min of 0.12534mpa and max of the 357.76mpa.

fig shows the directional deformation in the y direction and min of -0.019543mm and max of 0.47517mm.

fig shows the equivalent elastic strain is of the both ribs min of 4.0262e-05 mm/mm and max of 0.00085535mm/mm.

fig shows the min of the 1.4422mpa and the max of the 242.66mpa for the weld joints.

fig shows the factor of safety of min of 0.70466 and max of 15.

fig shows the contact status such as the over constrained,far,sliding,sticking.

fig shows the pressure of the min of 0 and max of the 47.018mpa.

fig shows the min force of 2.6666N and the max of the 2293N.

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".

fig shows the equivalent stress of min of 0.025919mpa and the max of 353.03mpa .

fig shows the directional deformation in y direction of the min of -0.019892mm and max of the 0.42403mm.

fig shows the elastic strain in the ribs of min of  5.1341e-06 mm/mm and max of 0.00056491mm/mm.

fig shows the equivalent stress in the weld joints min of 2.1725mpa  and max of the 238.22mpa.

fig shows the safety factor of the min of 0.6045 and max of 15.

fig shows the contact status of over constrained,far,near,sliding,sticking.

fig shows the pressure of min of 0mpa  and max of the 36.258mpa.

fig shows the min force of 1.9485N and max of the 2461.1N .

Comparision of the results

cases	Material	Equivalent stress(Mpa)	Elastic strain(mm/mm)	Directional deformation(mm)	force convergence(N)	Equivalent stress2 ( in case of weld joints)(Mpa)
1	stainless steel	Min:0.15753 Max:344.38	Min:0.00039643 Max:1.863e-05	Min:-0.024094 Max:0.37723	Min:2.5529 Max:2456.7	Min:2.9215 Max:283.14
2	Aluminium and stainless steel	Min:0.12534 Max:357.76	Min:0.00085535 Max:4.0262e-05	Min:-0.019543 Max:0.47517	Min:2.666 Max:2293	Min:1.4422 Max:242.66
3	Bronze stainless steel ,copper	Min:0.025919 Max:353.03	Min:0.00056491 Max:5.1341e-06	Min:-0.019892 Max:0.42403	Min:1.9485 Max:2461.1	Min:2.1725 Max:238.22

• The maximum equivalent stress by the material of aluminium and the stainless steel is that max of 357.76mpa.
• The highest equivalent stress in case of the weld joints is that contain the material of stainless steel of max 283.14mpa.
• The maximum directional deformation in the case2 ie aluminium and stainless steel is of max of 0.47517mm.
• The maximum elastic strain in the case2 is about the max of 4.0262e-05.

conclusion:In this challenge learnt about the various materials with properties and the comparision of the stresses at the plate section and the weld joints section and the elastic strain and the directional deformation in the y direction and then compare the results of these cases.