Analysis of Strength Parameter of Welded Joint Using ANSYS Workbench

Steel structures include different joining strategies including welding, which is utilized for some reasons. This is identified with the necessary time for the procedure execution and furthermore identified with the moderate expense with great dependability. These structures are oppressed during their life cycle, to variable burden parts because of the outer condition, (for example, wave and wind sway). Presenting the welded joints in structures exposed to fatigue loads makes a test to safeguard the structural strength. This circumstance needs superior information on fatigue conduct of the welded joints. Evaluating this conduct utilizing the fatigue tests is the most solid strategy; in any case, it requires a huge interest in time and assets, which make this arrangement not reasonable for a vast dominant part of mechanical entertainers in steel construction. Welding is a process that combines materials by heating them at reasonable temperatures with or without weight utilization or by using weight alone, and using or without filler material. Welding is used for the creation of permanent joints. It is used for vehicles, ships, rail cars, structural works, tanks, furnishings, boilers, general fixed works and ship buildings. It also is used for assembling car bodies. Welding is manufacturing or sculptural technique, which blends materials regular metals or thermoplastic, for example brazing and patching that do not liquefy the base metal by a mixture that is unmistakable from lower-temperature metal connection systems. Regardless of softening the base metal, the joints are periodically filled with the filler material forms a layer of fluid material (the weld reservoir) that refreshes to create a joint that is as solid as the base material. Weight can also be used in warmth or without the input of anybody else to create a weld.

The increasing demand for both high production rates and high accuracy has led to the provision of fully machined or automated welding processes. The pace at which automation is implemented in the soldering process is incredible and more automated machines than men in manufacturing units are expected to be found by the end of this century. Computers often play an important role in the operation of automated solder processes and the commands generated by the computer are derived from programs. Such programs require algorithms in the form of mathematical equations for the welding variables. To allow efficient use of the automated systems, a high degree of confidence is necessary for the prediction of soldering parameters in welded joints to achieve the required mechanical strength.

B, C and D are general grades of solder. The solder class shows how many errors the weld has and how the base material components both inside and outside have been misaligned. Welding class B is the lowest misalignment level which needs post-treatment in theory. Class B is used in high stresses of fatigue, high risk areas and fracture risk. Following welding Class C requires no post-treatment. It takes less time than class B. BT Products standard for welding class C. Class D is used in non-high load welds.

The first step in the simulation is to change the geometry so that a few bad parts are produced. Mild steel and weld Filler materials used Al 6061 were the actual material of the welding model used, the simulation material was chosen as a mild steel because it matches the most mechanical properties and is accurate enough. For the meshing process, the element type Hex dominant is used. It ensures that Hex elements but also other elements are preferably used for this approach to fill as well as possible the lack of geometry. The initial thickness size is fixed at 3 mm, 4 mm and 5 mm per part. The size of the elements is changed to verify the adequacy of the elements after the problem is solved. The present work has modeled various sets of geometrical assemblies. The first set is a simple' T' joint design, which is defined in the figure using the solid work and plate dimension. Secondly, assembly butt joint was designed. The thickness of the bead ranges between 3 mm, 4 mm and 5 mm.

Two plates are joined together by weld process. Plate size is 150 mm × 80 mm ×4 mm thick for butt joint. There is a chamfer provided by 45o, chamfer of 4mm × 4mm & 4mm thick. Dimension of ‗T‘ joint plate is 150 mm × 80 mm ×4 mm thick three plate joined by weld process to form a three shape. Weld bead having variations to its thickness.

Mild steel and Aluminum 6061 considered as material in present study. Mild steel material considered for metal plates and Aluminum 6061 welding material considered for joining the plates by welding process. Properties of material are described below.

The methodology adopted for static finite element analysis of the welded joints in ANSYS. Furthermore; boundary conditions, meshed models, and results of welded 'T' joint and butt joint are discussed. While welding has many distinct benefits over other joining processes, it suffers from several major drawbacks, such as residual stress evolution and solder distortions. The results of welding input conditions can be easily estimated by minimum experimental cost using simulation methods such as the Finite Element Method. A research was conducted to predict the complete transient temperature fields of a Mild steel plate‘s base, in a 3D finite element model.

Results have been presented in the form of total deformation, stress and strain generated under the load value considered. Fatigue analysis performed on ‗T‘ joint and butt joint and optimized factor of safety and fatigue life. Both joint having three type of model in variations of weld bead from 3mm, 4mm & 5mm. In present study two types of fatigue loading applied first one is fully reversed loading and secondly zero-based loading. Weld joints deformation analysis performed by applying 1000N load on the top of surface of ‗T‘ joint and horizontal plate fixed by both sides. Also, for butt joint one end of plate kept fixed and vertically downward load of 1000 N applied at the other end of plate. Then fatigue analysis formed for optimized stress and deformation of welded joint, after, results compare the data for optimization of welded joint strength.

As per graph we found the maximum deformation in butt weld joint at 3mm thickness. Minimum deformation found on 4 mm weld bead thickness. When using weld bead of 5 mm thickness deformation found 3.2175 which is lower from 3 mm thick weld and higher than 4 mm thickness of weld

As per graph maximum stress found on 3 mm thickness of weld bead and minimum stress found on 5 mm thickness of weld bead joint.

As per graph higher factor of safety found on 5 mm thickness of weld bead in welded joint and minimum FOS found on 3 mm thickness weld bead joint which is lower than as compared to other.

A number of the structural components are made of welded joints in containers, pressurized vessels, transport vehicles, earthmoving equipment, spacecraft, etc. In the manufacturing and construction of several structures, butt welds and' T ' joints are the most common. The extensive application of butt welds in different structures, including offshore and nuclear, offers scientists wide scope for analyzing the actions under different loading conditions [8]. Failure analysis of the elements shows that the principal cause of most destructive failures is fatigue alone [14]. Even if the fatigue of the sold metal is fine, there are problems. There is an abrupt change in the section which is caused by excessive solder regeneration, undercutting, layer inclusion and insufficient penetration. [7] The structural use of aluminum alloys in applications like automobiles and trains, bridges, overland structures and high-speed ships is becoming more and more significant. Sweating is the primary method of joining in all cases and fatigue is an important design criterion. It is, however, considered to have weak fatigue properties in weakened joints. Clear design guidelines are therefore needed to prevent fatigue failures in the welded structures of aluminum alloys. In addition to the basic design of new structures, the methods to evaluate the remaining lives of existing structures are also of increased interest. 24] This study suggested that the strength parameters of the butt-type welded joint were strongest as far as the mechanical properties of the weld joint were concerned.

• As per deformation study by graph we found maximum deformation in butt weld joint at 3mm thickness. Minimum deformation found on 4 mm weld bead thickness. When using weld bead of 5 mm thickness deformation found 3.2175 which is lower from 3 mm

weld bead. • Stress optimization in butt weld joint at 3 mm thickness found maximum as compared to other two. also, for 5 mm thickness of weld bead gives lower deformation is 996.09 mm. so as per study of deformation and stress we found 5 mm thickness of weld joint gives better strength parameters. • Strain found in welded joints is maximum at 3 mm thickness of weld bead and minimum strain found on 5 mm thickness of weld bead. • As per study minimum factor of safety found on 3 mm thickness of weld joint and maximum factor of safety found on 5 mm thickness of weld bead joint. • In fatigue life analysis using S-N curve analysis in ANSYS we found similar life of all weld joint that is 1x 10 8 at 1000 N load. • In butt joint we found satisfactory results at 5 mm thickness of weld bead.

• As per deformation study by graph we found maximum deformation in T weld joint at 3mm thickness. Minimum deformation found on 5 mm weld bead thickness. When using weld bead of 5 mm thickness deformation found 0.4876 which is lower from 4 mm and 5 mm thick weld. • Stress optimization in T weld joint at 4 mm thickness found maximum as compared to other two. also, for 3 mm thickness of weld bead gives lower stress is 229.39 mm. so as per study of deformation and stress we found 5 mm thickness of weld joint gives better strength parameters. • Strain found in welded joints is maximum at 3 mm thickness of weld bead is 0.00217 mm and minimum strain found on 5 mm thickness of weld bead is 0.00196 mm. • As per study minimum factor of safety found on 3 mm thickness of weld joint is 2.0308 and maximum factor of safety found on 5 mm thickness of weld bead joint is 4.0025 mm. • In Factor of safety analysis using S-N curve analysis found maximum FOS on 5 mm thickness of weld bead T joint and minimum FOS found 3 mm thickness of weld joint. thickness of weld joint and minimum found on 4 mm thickness of weld bead joint, so as fatigue failure we can say that 3 mm thickness of weld bead T joint having higher number of life cycle during cyclic loading. • In butt joint we found satisfactory results at 5 mm thickness of weld bead.

The scope of the present study was limited to the mechanical properties and microstructure of the welded joint and three other dissimilar joints involving various metals. Further studies can focus on the corrosion behavior of these four dissimilar metal weld joints as it is more susceptible to corrosion. Also fatigue analysis of the welded joints can be attempted and the results can be compared. Also, further experimental work can focus on Post heat treatment on welded joints to increase the austenite content which can help to obtain satisfactory corrosion resistance and mechanical properties on the dissimilar welded joints. More studies can focus on welding joint process with different dissimilar metals considering the scope of new development projects in especially in aerospace industries.

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Research Scholar, OPJS University, Churu, Rajasthan, India