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weld bead erroring out

weld bead erroring out

weld bead erroring out

(OP)
Good afternoon, I have a .256 dia hole in a flat surface with a 45 deg x .03 chamfer and I am putting a .250 OD tube into it and I am trying to put a filleted convex weld bead around it and it keeps erroring out on me.  It is saying that they are not contacting surfaces.  I have done this several times before, but with two fack threaded parts and that was successfull.  Thank you in advance to anyone who can point out to me what I am doing wrong.

RE: weld bead erroring out

In order for a weld bead to work your surfaces have to be in contact.  It sounds like you're saying that you have a 0.003 gap all the way around.  I think you'll have to fudge your hole size down to 0.250.  You can put a one-sided tolerance on it if it must be machined oversize.

RE: weld bead erroring out

(OP)
Thanks for the respnse handleman.  Well that explains why it is bombing out on me.  Silly me, I always thought that welds and brazes were to seal the gaps and joint parts together, guess I was wrong.  Thanks again.

RE: weld bead erroring out

(OP)
Alright, I made the tube to the same size as the hole.  Then I ran the weld bead set to fillet, canvex with a top surface delta of .025 and a radius .01 amd I select the tube and the chamfer and tried to finish but it keeps telling me the "weld radius is too large to fit the surrounding geometry and to try a smaller radius".  So I tried everything down to a .0005 radius and it always fails and gives me the same message.  What on earth am I doing wrong here?  Is there any solution?  At this point I am open to any suggestions or ideas.  Thanks.

RE: weld bead erroring out

Are you selecting the chamfer and tube surfaces?

On those sizes the Top Surface Delta should be about .005" and the Radius about .03"

cheers
SW07-SP3.1
SW06-SP5.1

RE: weld bead erroring out

BTW, the delta is the chord height of the weld convex, so should be much less then the radius.

cheers
SW07-SP3.1
SW06-SP5.1

RE: weld bead erroring out

(OP)
Thanks for the response CorBlimeyLimey, but that does the same old thing.  I get the old try a small radius message.  This is really fustrating, because it is the last thing I have to do before this little monster is finished.  I thing I have already pulled out half of my hair.

RE: weld bead erroring out

(OP)
I am trying to make some small changes in the radius now, but no success.  I select the chamfer first and the tube second if that matters.  Thanks.

RE: weld bead erroring out

Which version and SP of SW?

Which surfaces are you selecting?

cheers
SW07-SP3.1
SW06-SP5.1

RE: weld bead erroring out

(OP)
We are still on SW 6 SP4.1.  

RE: weld bead erroring out

What happens when you try the Flat or Concave options?

cheers
SW07-SP3.1
SW06-SP5.1

RE: weld bead erroring out

(OP)
Thanks again for the help.  I just tried both flat and concave  and got the good old radius message.  I tried both chanf=ging the radius by 10 each time from .04 to .01 and left the delta at .005.  I also did that wiht concex.  I hav enot had any good luck using cancave and this is the first time I tried flat.  Concave like to go deep down into the part for some reason so I have stayed away from it.

RE: weld bead erroring out

(OP)
Oh if it matters, the drill was made by the drill wizard and the tube is a standard extrusion and the chamfer was made by the chamfer tool.  nothing very fancy.  Just a little FYI.

RE: weld bead erroring out

(OP)
This gets stranger and more fustrating by the minute.  OK are you readt for this?  I got the lower to to go, but the two near the top won't go.  Is that strange enough for you?  I did  and they are both on the same surface and the holes are all the same and the tubes all go down .187 in to the hole.  Well, in 10 minutes or so, I guess I will go home and have several beers and wonder about this one.  I will double check to make sure that everything is exactly the same before I get out of here.  Any thoughts or ideas on this problem?  Thanks again for the help.

RE: weld bead erroring out

(OP)
Ok, I have check everything over and only one thing stands out, but not very much in my opinion.  These are tw U shaped tubes going from one hole in one body to one hole in a second body and the bodies are laying coincient to each other.  The depth mating was on the two lower holes, where the weld took.  Does that make any sense?  Am I being clear?  Any thoughts about this?  Thanks again for the help.

RE: weld bead erroring out

OK ... can you post an image. (FAQ559-1100: How Can I Show An Image In A Post) You started with a simple tube going into a simple hole. Now it's a pair of U-tubes going into multiple plates.

Also please confirm that this is an assembly and not a multi-body part?

cheers
SW07-SP3.1
SW06-SP5.1

RE: weld bead erroring out

(OP)
Thanks for the reply.  Here is the image, I think:
http://img247.imageshack.us/my.php?image=xmm2090rr8.jpg
This part is the simpliest part of the assembly.  As you can see the bottom two joints were created but the top two keep on error about the radius is too large.  Also I did try and put two equal didtance mates on one tube and it started erroring right away.  So I assume that more mates on the tube is not the answer.  Thanks again for the help.

RE: weld bead erroring out

(OP)
Good morning.  I have try some more mates on this thing and nothing help and I have also run the interference check on the assembly and there is not interference on the tubes and holes that there are in.  This is just a little FYI.  Any ideas on what I did wrong here?  Thanks again.

RE: weld bead erroring out

The image you posted does clear up what you are trying to do, but does not show what is causing the problem.

My guess is that the tube ends do not [u]exactly[/b] line up with their respective holes.
Were the tubes created bottom-up or top-down (in-context}?

Try re-positioning the problem holes in-context to the tube ends. (or the tube ends in-context to the holes)

cheers
SW07-SP3.1
SW06-SP5.1

RE: weld bead erroring out

(OP)
Thanks for the response.  I have already tried done that and I tried run the interference detect and no red showed up on the tubes or the holes.  If it matters the scetch that made the tubes was fully defined and the two extentions were set to be equal.  Also I changed the mates from one distance to 2 coincident using the outside edge of the tube to the edge of the drill point so they should be identical and still the same message.  This makes no sense to me.  Any thoughts?  Thanks again for the help, I do appreciate it.

RE: weld bead erroring out

I suggest you delete those tubes and create new in-context ones, using the hole axes to align the 3D sketch sweep paths.

cheers
SW07-SP3.1
SW06-SP5.1

RE: weld bead erroring out

(OP)
Thanks for the suggestion, but I think I got it.  If you change in the sketch, the length from2.18371 to 2.183705 then the dang thing works.  I don't think I have seen anything that needs that much accurace, six digit.  Well, i do have one last dumb question, is there a way to hide that text or should I say dimensions for the welds?  Thanks again for everything.

RE: weld bead erroring out

You can deselect the [v]View > All Annotations[/b] option, or unless you specifically need it, just delete it.

cheers
SW07-SP3.1
SW06-SP5.1

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