A Novel Simulation Methodology for Evaluation of Weldment Analysis Tools for Edge Weld Design Optimization

Welded joints play a critical role in ensuring structural integrity and functionality across engineering applications. A Solidworks 2023 includes new tools for analyzing edge weld designs, which are important for creating strong and long-lasting welded structures. However, there's no standard method for using these tools to improve edge weld designs. This makes it hard for engineers to get the most out of the software and can affect the quality of welded products. This study proposes an innovative simulation methodology that showcases the capabilities of Solidworks 2023 for evaluating edge weld designs, aiming to develop a comprehensive approach for edge weld optimization through advanced weldment analysis aligned with real-world applications. Using Solidworks 2023 student version, a three-dimensional frame structure model focused on edge welds was developed. The methodology involves defining welding processes and material properties, creating a 3D Computer-Aided Design (CAD) model of the edge welds, and setting appropriate boundary conditions and loading scenarios. The simulation revealed that several edge weld connectors exhibited calculated weld sizes significantly exceeding estimated dimensions, indicating potential weld quality or analysis parameter concerns. The weldment analysis outcomes were categorized as "Ok," "Needs attention," and "No solution." Several edge weld connectors required attention due to discrepancies between calculated and estimated weld sizes or instances of no solution. Recommendations were made to increase weld size or reevaluate welds to ensure structural integrity and performance. The weld simulation provided critical insights into the assembly's response to the applied loads, highlighting the importance of a standardized simulation methodology to fully leverage Solidworks 2023's capabilities, thereby enhancing the quality and functionality of welded structures.