What is the best way to integrate crack like structure into ansys model?

15 December 2024 1 5K Report

Hi everyone,

I recently started working with ANSYS Static Structural to simulate resistance spot welding geometry, focusing on integrating crack-like structures. My goal is to study the mechanical effects of these cracks by varying their location, length, and orientation.

To give you a clearer picture of what I am working on, I’ve attached two images:

A schematic of liquation cracking regions in the weld nugget and HAZ.

A meshed geometry model with an oval weld nugget and a highlighted potential crack location.

My Questions:

Would it be more efficient to create crack-like geometries in SpaceClaim by introducing voids or notches? If so, which tools or workflows would allow me to parametrize the crack dimensions (length, position, orientation)?

Alternatively, are fracture mechanics tools in ANSYS more appropriate for this task? For example, would methods like cohesive zone modeling or XFEM (Extended Finite Element Method) be better suited for studying the cracks dynamically?Hi everyone,

If you’ve worked on similar simulations involving crack behavior in weld geometries, I’d love to hear your insights:

Which method (SpaceClaim geometry modeling vs. ANSYS fracture tools) offers better flexibility for crack parameterization?
What challenges or limitations should I be aware of with either approach?

Thanks in advance for your suggestions!

Hossein Aliyari

The current model uses poor meshing, which is inadequate for capturing crack behavior in the weld nugget and HAZ. I have worked with Spaceclaim and HyperMesh to create spot welds, it is easy but believe me it's not worth tying especially if you're working on academic papers or projects!!!

to create the best modeling you can read my latest paper in which I compared different meshing and modeling techniques of spot weld modeling. Don't forget to read the references of my work you can find tens of other papers working on different modeling techniques! I also included a youtube video showing how to use a proper mesh for it!

To wrap up I recommend you Switching to XFEM for dynamic crack propagation without predefined paths and ensure extremely fine mesh in the nugget zone to capture stress gradients accurately (I also sent you a couple of papers for XFEM). Avoid using SpaceClaim or HyperMesh for crack modeling as it is inefficient for propagation studies.

Papers and Video:

Paper for different modeling techniques:

Article Fatigue Life Prediction of Spot-Welded Joints Using a Novel ...

YouTube video on the modeling of spot weld in lap joint:

https://www.youtube.com/watch?v=Y3GwjhlQutA&t=1s&ab_channel=FEAMaster

paper on XFEM spot welds:

Article Comparing and validating the numerical modeling of spot-weld...

Article Torsional Fatigue Performance of a Spot-Welded Structure: An...

Cheers,

Hossein

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