Week 3 Verification of Weld Joints for three different weld material by analysis in ANSYS

OBJECTIVE:- To perform analysis of weld joints for different material of weldments in ANSYS.

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.

PROCEDURE:-

• Open Ansys Workbench and choose static structural.
• In the Engineering data, let the material be stainless steel with default values.

• Now in the workbench goto Model -> Edit, in the model window check the Geometry for the material and assign Stainless Steel to plates, ribs and weldment.

• For the contact, the big plate, small plate and the 2 ribs have the frictional contact so the type= Frictional and Friction Coefficient= 0.2

• For the mesh, the small and big plate is selected for sizing with mesh element size 7mm.

• For the analysis settings, change the large deflection to On

• For the contact load, there will be 2 types one is fixed support which will be applied to holes of big plate and second is a force of 15000 N which will be applied to the hole of the small plate.

• Provide the required output request for the solution like directional deformation in the y-axis, Von-Mises stress in the body and on the weldments and Equivalent elastic strain in the body and on the ribs and click on solve.

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]

• All of the settings done in case 1 will be similar only in the material assignment Aluminium alloy (high strength, wrought) is added from Granta design sample material.

• The small and big plate along with ribs assigned Stainless steel

• All the weldments were assigned Aluminium alloy(high strength, wrought).

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".

• All of the settings done in case 1 will be similar only in the material assignment Bronze, cast is added from Granta design sample material, Copper Alloy from General Material

• The plates were assigned stainless steel material while the weldments were the Bronze, cast and the ribs were Copper Alloy.

RESULTS:-

Directional Deformation in the Y-axis

Stainless Steel- Weldments, Plates And Ribs

Aluminium Alloy- Weldments, Stainless Steel- Plates and Ribs

Bronze- Weldments, Stainless Steel- Plates and Copper- Ribs

Strain in the body

Stainless Steel- Weldments, Plates And Ribs

Aluminium Alloy- Weldments, Stainless Steel- Plates and Ribs

Bronze- Weldments, Stainless Steel- Plates and Copper- Ribs

Strain in the ribs

Stainless Steel- Weldments, Plates And Ribs

Aluminium Alloy- Weldments, Stainless Steel- Plates and Ribs

Bronze- Weldments, Stainless Steel- Plates and Copper- Ribs

Stress in the body

Stainless Steel- Weldments, Plates And Ribs

Aluminium Alloy- Weldments, Stainless Steel- Plates and Ribs

Bronze- Weldments, Stainless Steel- Plates and Copper- Ribs

Stress in the weldments

Stainless Steel- Weldments, Plates And Ribs

Aluminium Alloy- Weldments, Stainless Steel- Plates and Ribs

Bronze- Weldments, Stainless Steel- Plates and Copper- Ribs

Material	Max. Directional deformation in Y-Axis (mm)	Max. Equivalent Elastic Strain in Body (mm/mm)	Max. Equivalent Elastic Strain in Ribs (mm/mm)	Max. Equivalent Stress (Von-Mises) in Body (MPa)	Max. Equivalent Stress (Von-Mises) in Weldments (MPa)
Stainless Steel- Weldments, Plates And Ribs	0.35133	1.8514e-003	5.093e-004	340.31	302.38
Aluminium Alloy- Weldments, Stainless Steel- Plates and Ribs	0.36539	3.414e-003	4.9179e-004	344.93	251.73
Bronze- Weldments, Stainless Steel- Plates and Copper- Ribs	0.40618	3.3212e-003	7.1752e-004	351.19	265.28

So it can be observed that Case 3 having stainless steel as plate and copper as ribs experience the highest directional deformation in the y-axis, strain the ribs and stress in the body while Case 1 having stainless steel as plates and ribs experience the least directional deformation in the y-axis, strain and stress in the body but as weldments aluminium alloy experience the least stress and stainless steel experience the highest.

CONCLUSION:-

So it can be inferred from the analysis that stainless steel as a weldment experiences the highest stress in comparison to aluminium alloy and bronze whereas aluminium alloy experience the least.