Analysis and Optimization of T Shape Weld Joint Using FEA

Abstract

The weld joints are used in various types of mechanical and civil engineering structures to strengthen the joints. The strength of T shaped weld joint significantly depends upon the design parameters of weld joint. The current research is intended to investigate the T shaped weld joint using techniques of Finite Element Analysis (FEA). The FEA analysis is conducted on T shaped weld joint using ANSYS simulation package. The optimization studies are conducted on T shaped weld joint to determine the effect weld joint parameters on induced deformation. From the optimization studies, the dimensions corresponding to weld height is determined for maximum and minimum deformation of T shaped weld joint.

Introduction

I. INTRODUCTION

Welding is a process involving joining of dissimilar elements by heating at high temperatures. The welding process may or may not involve application of pressure. The type of filler material to be used depends upon type of welding. The welding process enables to make permanent joints in automobile components, railway wagons, machine components, machine components and other structural frames.

Tee joints are used when one part must be joined to the centre of another part forming a “T”. Like the other types of weld, there are several ways that this joint can be prepared and welded, each with their own benefits and disadvantages. Most methods of welding tee joints involve welding the two joints between the parts, with either a high or low energy density beam.

II. LITERATURE REVIEW

Wahab et. al.[1] have conducted experimental investigation on fillet weld joint to determine normal stress and shear stress under different misalignment conditions. The critical regions of fillet weld joints are determined from the research.

Lee et. al.[2] have conducted numerical investigation of cantilever beam with welded joints. The analysis was conducted under tensile loading conditions as well as axial loading conditions. The lateral deformation, transverse stresses are determined for Ludwick cantilever beam material.

Wilcox et. al.[3] have presented analytical theory on stress evaluation of weld joints. Different theories are proposed and out of all the fillet weld theory is found to be more pragmatic and in close agreement with various types of numerical results. The effect of longitudinal loading and oversizing of weld joints on corner stress is also evaluated.

Mahapatra et al. [4] have conducted research on filleted weld joint using experimental techniques. The effect of angular distortion on weld stress, notch stresses are evaluated. Various factors which can mitigate the induced stresses on weld joint is presented.

Kumose et al. [5] have conducted research on elastic straining of welded joint using both numerical and experimental techniques. The effect of pre-straining and post-straining on induced distortion of welded joints is presented. Different factors determining pre-strain and post-strain of fillet welded joints are determined. The effect of flange thickness on weld stresses is also investigated.

Michaleriset. al. [6] have conducted research on weldment using experimental techniques. The effect of thermal tensioning, preheating on weld stresses on distortion are investigated. Thermal tensioning works to “control residual stress and distortion by generating a tensile strain and the weld zone prior to and during welding by imposing a temperature differential” [6]. 

III. OBJECTIVE

The current research is intended to investigate the T shaped weld joint using techniques of Finite Element Analysis (FEA).  The FEA analysis is conducted on T shaped weld joint using ANSYS simulation package. The effect of weld height on lateral deformation of T shape weld joint is investigated using Taguchi optimization method.

IV. METHODOLOGY

The FEA analysis is conducted on T shaped weld joint involving different steps i.e. CAD modelling, meshing, boundary conditions and solution stage. The T shaped weld joint is developed in ANSYS design modeller using sketch and extrude tool. The T shaped weld joint is shown in figure 2.

Conclusion

The use of ANSYS simulation package can significantly reduce the time required to evaluate the strength of T shaped weld joint subjected to transverse loading condition. The FEA simulation of T shaped weld joint is conducted to determine critical regions from where the crack can initiate and cause catastrophic damage to the structure. The optimization studies are conducted on T shaped weld joint to determine the effect weld joint parameters on induced deformation. From the optimization studies, the dimensions corresponding to weld height is determined for maximum and minimum deformation of T shaped weld joint.

References

[1] T. Ninh Nguyen and M. A. Wahab, “The effect of weld geometry and residual stresses on the fatigue of welded joint under combine [2] Kyungwoo Lee, “ Large deflections of cantilever beams of nonlinear elastic material under a combined loading,” International Journal of Non-Linear Mechanics 37 (2002) 439–443. [3] Robb C. Wilcox, “The effect of weld penetration on tensile strength of fillet welded joints”,B.S., Naval Architecture and Marine engineering, U.S. coast guard acadamy, 1991 [4] Mahapatra, M., G. L. Datta, B. Pradhan, and N. R. Mandal. “Modelling the effects of constraints and single axis welding process parameters on angular distortions in one-side fillet welds.” Proc. IMechE 221 Part B: 397-407. [5] Kumose, T., T. Yoshida, T. Abbe, and H. Onoue. “Prediction of Angular Distortion Caused by One-Pass Fillet Welding.” Welding Journal. 1954: 945-956. [6] Michaleris, P., J. Dantiz, and D. Tortorelli. \"Minimization of welding residual stress and distortion in large structures.\" Welding Journal 11 (1999): 361-366s. [7] Okerblom, N.O. \"The Calculations of Deformations of Welded Metal Structures.\" 1958 (Her Majesty’s Stationery Office, London). [8] Teng, T., and C. Lin. “Effect of welding conditions on residual stresses due to butt welds.” International Journal of Pressure Vessels and Piping 75 (1998): 857-864. [9] Teng, T., C. Fung, P. Chang, and W. Yang. Analysis of Residual Stresses and Distortions in TJoint Fillet Welds. International Journal of Pressure Vessels and Piping 78 (2001): 523-538. [10] Tekriwal, P., and J. Mazumder. \"Transient and Residual Thermal Strain-Stress Analysis of GMAW.\"Journal of Engineering Materials and Technology 113 (1991): 336-343. [11] T. Lassen, ph. Darcis, and N. Recho,(2005) Fatigue behavior of welded joints part 1–Statistical methods for fatigue life prediction supplement to the welding journal, Sponsored by the American Welding Society and the Welding Research Council,pp.183-187. [12] Teppei Okawa, Hiroshi Shimanuki, Tetsuro Nose, Tamaki Suzuki,(2013) Fatigue life prediction of welded structures based on crack growth analysis, Nippon steel technical report no. 102, pp.51-53.

Copyright

Copyright © 2022 Ranjeet Singh, Er. Gora Ram Sharma. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.