Webinar below shows different methods to size welds: https://www.youtube.com/watch?v=K6MPCb6V02M There are basically two different groups of methods shown: one that doesn't require the weld to be explicilty modeled, and other that requires the weld to be modeled in the FEA. Modeling welds in FEA is prone to problems due to mesh density sensitivity and singularities. It's also impossible to do so for complex structures in aerospace, naval, big industrial plants. The webinar also shows a method that doesn't require the weld to be modeled. It is Weaver's Traction Stress Method. This has been shown to be inaccurate. I went through the webinar and several articles, and I can say with confidence that the software is currently outdated when it comes to weldment analysis. There are different processes for weld sizing, but the main methodologies are: - Blodgett's Method (Handcalc): Uses analytical solutions to calculate the weld from elementary mechanics. It predates FEA analysis and doesn't account for local flexibility, eccentric stiffness, stress concentration, load distribution, complex geometries. - Weaver's Traction Stress Method ((https://www.weavereng.com/feweld/dload/FEWeld_WhitePaper.pdf): Uses FEA and the traction stress state to calculate the weld. But the method is still sensitive to singularities and mesh density, and doesn't account for the local effect of the weld because it's not modeled in the FEA analysis. This has been proved to result in significant errors. Also, the methods above assume the resisting throat is at 45°. This has been shown to be incorrect for welds with high shear loads in the longitudinal direction. - Explicit Weld Modeling: Uses FEA with the weld modeled. It's prone to problems due to mesh density sensitivity and singularities, that cause peak stresses in the weldment that are not real. All of these have been improved in Dong's Traction Stress Method (https://backend.production.deepblue-documents.lib.umich.edu/server/api/core/bitstreams/493b8549-b9c3...). This is the state-of-the-art, and the major improvements are: - It's not significantly affected by singularities, which is a common problem for analyzing welds when they're modeled in the FEA. - In the publication above he created a fillet weld element for FEA that eliminates the hassle of modeling welds in the FEA, while the element itself still retains the structural effect as if the weld was there. - His method accounts for the fact that weld failure changes from 45° to 22.5° depending on the loading condition. The difference is significant. I have been able to eliminate weld distortion problems and save a lot of money just because I'm not oversizing my welds anymore, which is what the old methods do. Unfortunately, to use it in Inventor Nastran in its current configuration, I have to explicitly model the weld. But the article above shows the formulation for a weld element that eliminates the need to do this. My suggestion is to implement it in Inventor Nastran so weld sizing can be done properly.
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