Question

Calculate the weld bead all contour, from the base of a handlebar that is a 3 "square axis on each side as shown, on a cylinder where P = 400 Ibf. Use A36 steel, AWS 6010 electrode and unskilled welder.

Р 8" 10" Base cuadrada soldada

square welded base=base cuadrada soldada

Answer 1

- MA: Static Structural - Mechanical [ANSYS Multiphysics] File Edit View Units Tools Help -+: Solve - ?/Show Errors ?/ Review Model (Beta) F Abd Worksheet in Show Vertices Wireframe Show Mesh H Random Colors Annotation Preferences E ANSYS R15.0 Il Edge Coloring hdkh KH - Thicken Annotations Environment Inertial - Loads - Supports - Conditions - Direct FE Joint Configure Configure . Assemble A= 0 Set Revert Outline 1 A: Static Structural Filter: Name Static Structural Project Time: 1.5 Model (A4) 7/31/2020 9:42 AM # Geometry Coordinate Systems A Fixed Support Connections B Force: 400. Ibf - Contacts Mesh Static Structural (A5) Analysis Settings Fixed Support Force Solution (A6) Solution Information Equivalent Stress Total Deformation Stress Tool Safety Factor | В 0.000 5.000 10.000 (in) 2.500 7.500 Details of "Static Structural (A5)" Definition Physics Type Structural Analysis Type Static Structural Solver Target Mechanical APDL Options Environment Temperature 71.6 °F Generate Input Only No Geometry & Print Preview, Report Preview Graph 1 Tabular Data 1. Messages Graph O No Messages No Selection U.S. Customary (in, lbm, lbf, s, V, A) Degrees rad/s Fahrenheit 9:44 AM 7/31/2020 O Type here to search o 1 O SW

- MA: Static Structural - Mechanical [ANSYS Multiphysics] File Edit View Units Tools Help + - Solve - ?/ Show Errors ?/ Review Model (Beta) F Abd Worksheet in N Show Vertices Wireframe Show Mesh Random Colors Annotation Preferences Display ANSYS R15.0 Unit: psi II Edge Coloring WARAKA I Thicken Annotations Result 1.0 (True Scale) HAXHIN 123 Probe All Bodies Joint Configure Configure Assemble A= 0 Set Revert Outline A: Static Structural Filter: Name Equivalent Stress Project Type: Equivalent (von-Mises) Stress Model (A4) Geometry Time: 1 Coordinate Systems 7/31/2020 9:44 AM Connections Contacts 2907 Max Mesh 2584 Static Structural (A5) 2261 Analysis Settings 1938 Fixed Support Force 1615 Solution (A6) 1292 Solution Information 969 Equivalent Stress 646.01 Total Deformation 323.01 Stress Tool 0.016183 Min Safety Factor 0.000 5.000 10.000 (in 2.500 7.500 Geometry & Print Preview Report Preview Graph Tabular Data Details of "Equivalent Stress" Scope Scoping Method Geometry Selection Geometry All Bodies Shell Top/Bottom Layer Entire Section Definition Type Equivalent (von-Mises) Stress By Display Time Last Calculate Time History Yes Identifier Suppressed No a Integration Point Results Animation 10 Frames Time 0. 1. Messages Graph O No Messages No Selection U.S. Customary (in, lbm, lbf, s, V, A) Degrees rad/s Fahrenheit 9:44 AM 7/31/2020 1 Type here to search o O SW

- MA: Static Structural - Mechanical [ANSYS Multiphysics] File Edit View Units Tools Help .: - Solve - ?/ Show Errors ?/ Review Model (Beta) # Abt Worksheet in N Show Vertices Wireframe Show Mesh PH Random Colors Annotation Preferences Display All Bodies ANSYS R15.0 II Edge Coloring WARAKA I Thicken Annotations Result 1.0 (True Scale) MAX HIN 123 Probe Joint Configure Configure . Assemble A= 0 Set Revert Outline A: Static Structural Filter: Name Total Deformation Project Type: Total Deformation Model (A4) Unit: in Geometry Time: 1 Coordinate Systems 7/31/2020 9:44 AM Connections Contacts 0.0021302 Max Mesh 0.0018935 Static Structural (A5) 0.0016568 Analysis Settings 0.0014201 Fixed Support 0.0011834 Force Solution (A6) 0.00094674 Solution Information 0.00071006 Equivalent Stress 0.00047337 Total Deformation 0.00023669 Stress Tool O Min Safety Factor 0.000 5.000 10.000 (in 2.500 7.500 Geometry & Print Preview Report Preview Graph Tabular Data Details of "Total Deformation" Scope Scoping Method Geometry Selection Geometry All Bodies Definition Type Total Deformation By Time Display Time Last Calculate Time History Yes Identifier Suppressed No Results Minimum 0. in Maximum 2.1302e-003 in Animation 10 Frames 0. 1. Messages Graph O No Messages No Selection U.S. Customary (in, lbm, lbf, s, V, A) Degrees rad/s Fahrenheit 9:44 AM 7/31/2020 O Type here to search o O SW

- MA: Static Structural - Mechanical [ANSYS Multiphysics] File Edit View Units Tools Help + - Solve - ?/ Show Errors ?/ Review Model (Beta) F Abd Worksheet in N Show Vertices Wireframe Show Mesh Random Colors Annotation Preferences All Bodies ANSYS R15.0 II Edge Coloring WARAKA I Thicken Annotations Result 1.0 (True Scale) HAXHIN 123 Probe Display Joint Configure Configure 2 Assemble A= 0 Set Revert Outline A: Static Structural Filter: Name - Safety Factor Project Type: Safety Factor Model (A4) Time: 1 Geometry 7/31/2020 9:44 AM Coordinate Systems Connections 15 Max Contacts 12.473 Min Mesh 5 Static Structural (A5) Analysis Settings Fixed Support Force Solution (A6) Solution Information Equivalent Stress Total Deformation Stress Tool Safety Factor 0.000 5.000 10.000 (in 2.500 7.500 Geometry & Print Preview Report Preview Graph Tabular Data Details of "Safety Factor" Scope Scoping Method Geometry Selection Geometry All Bodies Definition Type Safety Factor By Time Display Time Last Calculate Time History Yes Identifier Suppressed No Integration Point Results Display Option Averaged Average Across Bodies No Animation 10 Frames 0. 1. Messages Graph O No Messages No Selection U.S. Customary (in, lbm, lbf, s, V, A) Degrees rad/s Fahrenheit 9:44 AM 7/31/2020 Type here to search 1 o O SW
I have done analysis using the 0.25 inch fillet weld bead and the results shows maximum stress induced in the weld bead is 20 MPa which is quite below the yeild point of the weld material.

Also the factor of safety is 12 which is very good. Hence the design is considerabe