Hi Mark,
I've put an example in customer-files (using the same subject). First I
made a weldment assembly using the groove weld tool to get the desired bead
geometry. Please examine the padeye component and note the split features I
used to define the bead surfaces and the work features that control the
beads fill direction. After this I created a new part and derived in the
weldment. The FEA was performed on the derived assembly in Inventor 10
professional. I'm not sure if this will be successful in your FEA software,
or even if I did it accurately. However, it might give you some news ideas
on how to get around the fillet tool limitation.
Regards,
Harold Lee
Inventor QA