Verification of Weld Joints

AIM:

• To perform Static Structural analysis on weld using different materials and obtain the results.

OBJECTIVES OF THE PROJECT:

• To define material for the weld.
• To define contact faces for the weld.
• To define fixed support and apply force on the plate.
• To perform mesh on the plate, ribs and the welds.
• To define face sizing for fine meshing on the ribs.
• To evaluate the maximum stress, strain and deformation.

PROCEDURE:

• Case 1 -
• OPEN > WORKBENCH > NEW PROJECT > STATIC STRUCTURAL.
• This will define static structural project.
• Now, go to ENGINEERING DATA > EDIT > ADD > STAINLESS STEEL.
• 
• Go to GEOMETRY > IMPORT > BROWSE > WELDING.STP.
• 
• This will import the welding geometry.
• Then, DOUBLE CLICK ON MODEL. This will open the mechanical module.
• Assign material as Stainless steel to all the components.
• 
• Go to CONNECTIONS > CONTACTS > PLATE AND RIBS > TYPE > FRICTIONAL > FRICTION COEFFICIENT = 0.2.
• 
• Now, go to MESH > ELEMENT SIZE = DEFAULT.
• MESH > INSERT > SIZING > ELEMENT SIZE = 7MM > SCOPE > RIBS > GENERATE MESH.
• 
• This will create mesh on the geometry according to the element size.
• Now, go to STATIC STRUCTURAL > ANALYSIS SETTINGS > LARGE DEFLECTION = ON.
• 
• Then, STATIC STRUCTURAL > INSERT > FIXED SUPPORT > SCOPE > ALL THE HOLES ON THE BASE PLATE.
• 
• Then, INSERT > FORCE > TYPE = COMPONENTS > Y = 15000N > SCOPE > THE SLOT FACES ON THE SMALL PLATE.
• 
• Go to SOLUTION > INSERT > STRESS > STRAIN > DIRECTIONAL DEFORMATION.
• 
• Go to SOLUTION > SOLVE.

• Case 2 –
• For the second case, we have to assign Aluminium alloy as material for the weld and Stainless steel for the plate and ribs.
• NEW > STATIC STRUCTURAL > ALUMINIUM ALLOY.
• Now, go to ENGINEERING DATA > EDIT > ADD > STAINLESS STEEL and ALUMINIUM ALLOY.
• 
• Share the geometry from case 1.
• This will import the welding geometry.
• Then, DOUBLE CLICK ON MODEL. This will open the mechanical module.
• Assign material as Stainless steel to the plate and rib components and assign Aluminium alloy to the welds.
• 
• 
• Then repeats the steps as in case 1 and solve the model for Aluminium alloy.

• Case 3:
• For the third case, we have to assign Bronze as material for the weld and Stainless steel to the plates and Copper to the ribs.
• NEW > STATIC STRUCTURAL > BRONZE.
• Now, go to ENGINEERING DATA > EDIT > ADD > STAINLESS STEEL, BRONZE and COPPER ALLOY.
• 
• Share the geometry from case 2.
• This will import the welding geometry.
• Then, DOUBLE CLICK ON MODEL. This will open the mechanical module.
• Assign material as Stainless steel to the plates and copper alloy to ribs and Bronze to the welds.
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• 
• Then repeats the steps as in case 1 and solve the model for Aluminium alloy.

RESULTS:

• Case 1 -
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• Case 2 -
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• Case 3 -
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COMPARISON TABLE:

	Stress (Mpa)	Strain (mm/mm)	Deformation (mm)	Weld stress (Mpa)
Case 1	303.31	7.2289E-4	0.31513	287.42
Case 2	307.3	7.0661E-4	0.36551	231.7
Case 3	311.81	9.436E-4	0.39191	240.9

• For case 1:Stainless steel, the stress in the weld is maximum.
• For case 2:Aluminium alloy, high strength, the weld stress is leeass as compared to the case 1. The material being strong, reduces the stress.
• For case 3:Bronze, the stress is slightly more than the aluminium alloy but less than the Stainless steel.
• Hence, for better strength Aluminium alloy with high tensile and yield strength provides good results.

LEARNING OUTCOMES:

• To insert material.
• To insert fixed support.
• To apply force.
• To insert face sizing in meshing.
• To request for the Safety factor.

CONCLUSION:

• Hence, by performing this project we conclude that the simulation on the weld material is performed using different materials in ANSYS.