How to Determine Weld Sizing and Analyze Strength with SOLIDWORKS Simulation

okay thank you as Bev said my name is Tess filmin I'm going to be application engineers here at Lenox specializing in simulation so we'll get started with weld sizing a strength calculation so I just kind of wanted to start off here talking about the different types of edge weld connectors that we have in SolidWorks simulators in SolidWorks Simulation it's kind of wanted to start out with the different types of edge weld connectors available so we have Phillip welds and groove welds Phillip welds example shown here on the right join two metal parts together at a right angle as you can see here we also have groove welds which can join to or apply to a preformed opening or a groove between two metal parts as shown here so we have both single and double sided so you can see here examples of double-sided fill it and groove welds edge welds can be applied between two shell features or one shell in one solid feature so this could be these could be two shells here or this could be a shell and this could be a cell the terminated part we call this the terminated part here always has to be a shell so some of the terminology that we'll be using today one of the main functionalities of Edgeville connectors is that we can look at weld sizing so when we talk about weld sizing and weld throat this kinda illustrates we're talking about here so the weld size for a Filat weld is defined as the distance from the root to the toe which is also sometimes called the weld leg and then for a groove for a groove weld it's the dimension of the joint penetration as shown here and then the weld throat is always from the root to the face of the weld in both cases so that's what that's got some of the terminology we'll be using I'll jump in to open up SolidWorks here and we'll get right into showing example here so this is kind of a simple example that will just illustrate some of the basic concepts and then we'll actually get into looking at a more complex and realistic example so kind of the overview in the objectives today is I'm going to introduce edge weld connectors explain sort of when and how they can be used in SolidWorks Simulation and like I said I'm going to show this simple example then we'll move into a more complex example before we get into some of your questions so first thing I'm going to do here is I'm going to start a new simulation study I just go up to study new study and I can name it whatever I want to solve name it webinar and again I've chosen static down here because it's just going to be a linear static simulation and you'll see here that I've got a few parts listed up here in the parts area so I've got the torque tube which actually consists of shell tube and this shell piece here which is a little support and then this back piece which is a solid I also have a bend piece here and another pipe these are both shells and then a back plate so first thing I need to do is I need to first thing I need to do is define a thickness here for all my shell features so I'm gonna go ahead and select all the shell features right click Edit definition and I can select you know any any thickness I want here I'll just pick an arbitrary 0.1 inches all right and then of course when I created a new study I have the default global contact global bonded contact I'm going to delete that out here because I'm actually going to create my own contacts and connections using the edge flow connector so to get into edge web connectors I just right click on the connections folder here and just working right down the tree so I'm in connections right click and down here you'll see edge will and as I open that up you'll see first options I have here is a little drop-down menu I get all the four types so I've got fill it and grooves single and double sided and I'm going to start out here on this side I'm just going to work my way around the piping here I'm going to in this because I'm going to create multiple edge welds so the first one I'm going to do up here on the on this edge right here is a will be a fill at a single sided fill it so I select that from the drop-down next thing you'll see is I've got to face sets to select so I always want to pick the terminated part in face in set one so the terminated part in this case since this tube is terminating in this flat plate the tube is determinated apart so I'll pick this and you'll see on the screen there on the right there's a little mouse picture of a mouse with a blue arrow on the right mouse button if I right click you can see on the left it dropped my selection down into the next window so that allows me to make these selections on the fly I can just create multiple edge weld connectors as I'm moving around it allows me to work very quickly so again I select face set two which is this back plate and you'll see that right mouse button blue arrow again it drops it down to the intersecting edge which is my final selection here so I'll select this intersecting edge and now you'll see that the area where the edge weld is defined is highlighted in this purple line you'll also see a yellow sphere down here that shows the beginning and the end point of my edge weld in this case and then a red arrow showing which to which side of the shell feature that the weld is located on I can change that over here in my weld orientation so I'll do here is I can show you down here in the weld orientation I'm on slide one right now if I select site two you can see that that red arrow flips to the inside so I can flip back and forth the weld orientation I'll keep this one on the outside moving down into the weld sizing area I have two options here I have the American Standard in the European standard so looking through the American standard the first selection I have here is the electrode so I can select from steel types up here and aluminum down here and you'll see if I have one of the pre-selected electrodes chosen it'll gray out this weld strength area it'll automatically fill in that will strength then I can choose the units as well so right now I'm showing 460 weld strength of thirty-nine thousand six hundred psi if I want to create a custom you like to a material or if I have a different material I select that right here this is no longer grayed out and I can specify the weld strength right there so we'll just go ahead and select an aluminum electrode and then moving down you'll see under the safety factor I have two default options here and I'll kind of show you what what those are referring to so the safety factor what it does is it reduces the allowable it shear strength of our electrode material when it's doing the pass/fail check so I have the ultimate shear strength of my electrode material divided by a safety factor which gives me an allowable shear strength that this solver will compare against the actual shear forces that the weld is seeing at that location and it will help determine if I have a pass passing or failing weld in that area there's two default options down here and you'll see it right here I have the American national standard for Automotive lifts which is a automotive lift Institute code and if I hover over this you'll actually see it says as per b15 3.1 the actual code where that comes from and then I also have the an a SME code and both of those two default options have us a default safety factor so for the American national standard for automotive lifts I have a safety factor 3 by default and then the other option I have a safety factor of 5 I can also enter any other value that I want so if I go down here I can actually type in whatever safety valve safety factor value that I choose and then my last selection is the estimated wealth size so I can choose to put this or not if I check if I uncheck this it gets grayed out but I can put in what my estimated wealth size is for that well and that will serve to give me a comparison so that the solver can tell me if I'm passing or failing on my estimated wealth size and that'll make a little bit more sense when we get to the results but basically it's going to show me a comparison between what the solver calculates I need and what I'm specifying here so we'll go ahead and create that first one now zoom in here and I'll create the next one this one will be a double-sided filler so again I need to pick the terminated part first right click and you'll see this one actually automatically detected that edge there and pre-selected it for me that intersecting edges window and I'll leave everything else in the world sizing section the same and now I have two more wells here that I'm going to create that are going to be groove welds because I have two parallel parts coming together so I'll pick single sided groove oil I think I selected the wrong ones there there we go and again another single sided groove well and then the last one I'll zoom in and just create the final fill it weld on this face here so again I pick the terminated part the next part and the edge okay so you can actually see here highlighted in blue all of my defined welds in there and then if I go over and look in the simulation tree there's a new folder under the connectors folder here called edge weld group one so I can actually if I wanted to create them separately I could group these by type or however I wanted to by location or material or whatever however I wanted to group them so I just have one edge weld group here showing all five of my edge welds okay and then now we need to create some fixtures and loads so we can actually test this right now everything's unconstrained so we'll put some fixtures in here so I'll fix this back face here and then I'll fix this bottom edge support right there and then we'll just put in maybe some unrealistic but just kind of some arbitrary loads just to show the the effect of the edge welds here so I'll put a gravity load so it's under its own weight and then I'll put a force on the top of this side here now that we have everything to find I can just go ahead and run this okay you'll see everything ran and now I'm showing a vine BC stress plot here so I'm going to turn off these other symbols we can see little bit better so right now I'm showing a stress plot if I right-click on my results folder this is where we actually get into the the weld check plot here so if I right-click results there's an option up here to find weld check plot I have a few options in here so I can include a title text so I'll just call this weld sizing and I can also associate a view orientation so I'll pick the top view click OK and now you see I'm looking at a top view showing all the welds on here and I'm what it's showing up here in my check plot is that I have three welds that need attention and two welds that are okay and so if I actually highlight one of these I've got a jeweled connector one highlighted it's showing me on here it needs attention because the calculated weld size is 0.33 inches whereas the estimated wealth size that I entered was 0.25 inches I can cycle through and actually see all of the ones that are showing they need attention here you can see this 10.26 versus my point two five the two that are okay are actually showing this one is point zero about point zero four inches this one is 0.24 seven now if i click details over here it will actually bring up some more details about the forces and moments on the weld at that location so right now it's showing me that where the edge goal is located and it's showing me the weld size the weld throat size and some of the forces and moments on the weld of that location so we can actually take a look at what it's showing us here so the calculated weld forces these are the four outputs that it gives us in that check plot so the joint normal force is this one right here it's actually normal to the intersecting shell edge so it's this outward normal then I also have a shear weld axis force which is this one here that's actually parallel to the weld seam and I have a shear surface normal force which is along the surface normal axis that's this one right here and then lastly I have the bending moment about the local weld axis so that's what it's showing me right here it will show the min and Max values of all those forces and moments as well as the mean now I can output this to an excel file you to do that and it'll output all those values I can also click right here and get a plot of the calculated required weld size and we'll throw out size along the the weld seam distance here so starting from where that yellow sphere was located when we define that all the way around to the end of the weld seam so this is showing the position along weld seam distance on this on the x axis here and this is showing me the well required weld size and weld throat size here so you can see that it Peaks right here at about 0.33 inches example the other thing you can notice here is when i zoom in these are all colored by pass/fail so you can see this one and these two over here are showing red those are my failing welds that were calculated as requiring a larger weld size than I had actually input and these two are showing in green because those are passing so this is kind of a simple example we'll take a look at a little bit more complex example so this part is actually from a excavator so this is where the cab would sit then there's actually a lifting arm located back here attached to these hinge points here so what we'll take a look at all of this is welded in here so the first first study we'll do is just a static study looking at everything as a bonded contact will kind of look at where the high-stress regions are and then we'll actually create some weld connectors in those locations to check our weld sizing and determine if we have a strong enough weld net location so this study has already been created for us I actually set this up ahead of time but I kind of step through showing what it is so all of these parts have already been converted to shell and they've already had a thickness assign and you can see the material here is plain carbon steel under our connections we have several context sets here so I just highlight them so you can see all the welded locations have been defined using a local bonded contact sets here and in this case we're not using any weld connectors we're just defining all the welds with bonded contacts we've also I've also defined on the backside here at these hinge locations have defined some reference geometry fixtures to basically constrain these radially and actually so they're only allowed to move as a hinge and then lastly we have a gravity force the downward direction here and then a remote load actually located if you can see this here this is actually modeling the force that would come from the cab sitting on this platform here so you can see most of the forces in the downward negative y-direction and then there's also some side loading in x and z directions so i've already run this study so I'll just show you I'll throw up the results right here so you can see the largest highest stress areas are in this Bend region here and actually this side has higher because of that side loading that's pushing it in the X and z directions here so if i zoom in you can actually see this is the highest stress region on the part and this seam right here is actually welded so this is the area that we're going to focus on and apply the edge well connector to check our weld strength of a location so what I could do is just right click on the study and duplicate it so I'd have all the same settings then I can go ahead make my changes so I've already done that here I have a separate study called weld sizing everything here is the same I've just there's you'll only see this edition right here so there's a new connectors folder where I've added the edge weld connectors so you can actually see I have three edge weld connectors in here located right in this region where we just show the high stresses and if I right click and kind of show the setup here so it's a single sided Filat weld and you can see the faces that were selected here and then that edge showing right there and it's oriented on the upper side here I've selected an electrode steel electrode and as input a safety factor of two and an estimated weld size of a quarter-inch and that's the same for all three segments here it gets if I hover over one of these that actually lists all that information so I can see it in the viewing area as well so that's the only change I made I replaced the bonded contacts with edge well connectors in that region so I can check mine so I can get that will check plot so I've already run this as well so we'll take a look at the stress on this one again we see the high stress area over here but now I can also view my weld check plot that I've created so you can see up here I have two two welds that need attention and one that's okay so you can actually if I click on that one it shows me right here this first segment here is passing right now it's calculated weld size of 0.2 3 inches so just under my estimated 0.25 the others that need attention are just over that so 0.25 four and point two five eight eight and again I could check those using my plot right here so you can see this one the max is about 0.23 and for my failing welds so if I go up here and select go down to my second connector here you can see that the first about two inches of the weld along the weld seam is where I have that above quarter inch calculated weld size okay so those are two examples kind of showing a simple example and a little bit more realistic example of how we can use the edge well connectors to estimate or determine our acquired weld sizes and check our weld strength based on the forces and this in those locations one more thing I wanted to show here was some different alternative methods for modeling welds so an edge mode connector basically creates a bonded contact in that along that edge so here I'm showing I've got basically a beam here with a base plate and I've defined this using an edge well connector so if I look at my stresses here and I'll actually turn off the symbols we can see it there you can look at the bottom I see stress over here again you'll see these you'll see these singularities along the edge that's going to happen anytime we have a bonded contact along an edge if I compare this this was the edge bail connector if I compare this with just creating a bonded contact on that edge I get basically the same results so I'm just showing there a bonded contact is basically doing the same thing as the edge weld connector the difference would end of the real functionality of a jewelled connector is we get that edge will or sorry that well check plot so we can check those forces in them in that area the only other alternative we would have would be to actually model fully model the edge well and I'll show that here and I've kind of isolated the well but again we'll still get those singularities on that on that edge and in those high-stress regions basically if you think of it like the stress is basically a force over an area and at the area in those regions is going to zero so in any type of Fe a will always have singularities along those edges so something to note when you're doing you know any type of simulation involving welds if you see those hype those local high stress regions just realize that that's most likely a singularity due to that due to the sharp edge there so that's all I had if there are any questions I can address those at this time hey Tim yes well Kim can you hear me yeah this is a Dean Schultz with Lennox okay I've got the questions out from here some people to ask we might not have time to answer all of them but we can certainly run down the list here and there so there's a handful of difference term men um at the end I guess we started about seven minutes late so we are running a little bit over that's fine though so here's a couple questions as well maybe um does the edge weld connector work where gap is modeled in you can use an edge well connector in a gap as long as the gap is not too too large and the reason is that those the equations that the edge well connector calculations are based on is for a basically in contact so the edge well connector that is is is meant for in contact welds you can use it where there's a gap as long as the gap is is not too big and actually 100 degree would that be acceptable 0.03 you lowers a gap poriyal Ganges yeah it would I guess it would depend on the situation the orientation of the parts sometimes plays a role in whether it will let you select those edges for an edge well if you can't select it for an edge weld connector you can still create a bonded contact in the region you just won't get the edge will check plot and then a couple things about the safety factors um there are the factors of safety are they defaults in two three and five them can you can they be changed so if I jump back a slide here the the defaults for these these are the two default options and they have default values of three and five but again you can enter any value you want if I jump back here right I can go in and I can override that down here it converting a solid to a shell yeah all's that done okay so right here if I right click I can define shell by selected faces and what I'd actually do is I go in and pick a face that'll be the shell face and then I can go in and specify thickness right here and if I if the parts were created in sheet metal but actually come into celebrex emulation add shell automatically great well how do you audio you select the faces and edges for the edge welds in the second example in this example yeah I believe that was a sight yep sure okay so we'll take a look here so in this case face one was actually this bottom face right here this is the terminating face phase two was this whole everything it's blue right here this this side piece right here and then it automatically detected that edge between those faces and I've got time for a couple more and then I look one says here I like how SolidWorks shows us the three organ thought you know forces maximum in a beach but can we see a vector addition some of those forces and where they were along the wild those forces and some reach their Max and min values so to get the resultant force it's not going to plot that automatically but you can basically figure out what the resultant force would be because you have all the like you mentioned the orthogonal forces here so you could you know you have the components of the resultant vector as far as the forces along the well that's kind of what it's showing in the check plot so the areas where it's got showing the highest calculated weld size required that's going to be the area with the highest forces acting on it so obviously probably not going to vary your weld size along the scene I'm probably going to pick the max here so in this case might be you might pick point two for you know quarter inch something like that but this is kind of showing you how the forces roughly showing you how the forces are varying because it's calculating the required weld size along that scene now I'm going to wrap up with this last question here and then on the ones that didn't get answered we can go back to everybody because we have the person who asked the question but there's one talking to people asking about stitch well so go all the way around and like they use a lot of Wells they say we're going like 1 inch wild every 3-inch RV 9 inches or something like that is there a good way to do that stitch well there's no way to directly model stitch Wells using you can't use an edge well connector you could possibly do it with a bonded contact you have to set up some local bonded contacts that's there or you could also potentially model actually model the stitch weld with a kind of like I showed here with using a fill it so if you did a fill it and then pattern that along that edge they may may be a way you could do it but no there's no way to directly do a stitch world there are spot welds in SolidWorks to do two flat surfaces but that's the only type of weld connector okay well I put the product side here and then I'm going to wrap it up for you excuse me you know arm thanks for attending it everyone and we've got questions get back to you on and we'll certainly do that just so you know there's a couple of things we would like to do we've been doing these webinars over time and we'd like to use your topics so one thing if you like some different topics that you'd like us to do you could send those to us at info at and same thing with enquiries as far as if you'd like to learn more about simulation there's the info at alliant XCOM but also if you'd like to learn more about the other products feel free to either you go over your sales rep or you can just go to info at align XCOM we can talk about what comes with the sides of the world sizing capabilities but all the other kinds of simulation that you might be interested in and then there is some special pricing as far as if you're buying a seat of SolidWorks right now just know that you could buy the simulation professional for a thousand dollars and add that in and you know big fix savings of money right now you can exist upgrade existing license that you have also so any of those kind of questions feel free to get get all of us and and we'll get back to you again though make thank you for attending and at the same time please send any al feedback you have to us and we'll take that in consideration and try to put the next no shows on your topics thank you everyone

Channel: Alignex, Inc.

Views: 82,625

Keywords: Weld sizing Solidworks Simulation, Alignex simulation webinar, Edge Weld Connectors SolidWorks Simulation, Stresses along Weld Seams SolidWorks Simulation, Weld Seam forces SolidWorks simulation, Simulation check Plots for welds, Weld methods in CAD FEA, SolidWorks Weld Simulation, SolidWorks Weld Seams, SolidWorks Weld Bead simulation, Solidworks Weld force analysis

Id: VBufskAVzmk

Length: 32min 21sec (1941 seconds)

Published: Fri Mar 27 2015