Hey everyone, I'm new to this community and also new to coding in Ansys. I'm looking for help with creating a script to evaluate welds and avoid artificial stress concentrations, especially in corners. Here's what I'd like the script to do: * **Inputs: **Provide the script with a predetermined path and the weld thickness in that area. * Functionality: The script should generate a stress graph using data from the path and identify the interval where the data is linear to create a line. I'd like an option bar to tweak the sensitivity formula for selecting data points to create the line, or have the ability to manually set the interval of data points. * Interpolation: From this line, the software should interpret the weld thickness and output the corresponding stress value at the weld location on the line. * Output: The script should produce a graph showing stress values along the path. It should also plot the created line for accuracy verification, with a marker to indicate the point of stress at the weld. Additionally, the graph should highlight the interval of data points used to create the line and mark the weld thickness on the axes. It should also add a note with the stress value at that weld thickens on the line. I'd like the option to number each data point (like 1, 2, 3, ...) to manually set the interval if that's easier. I'm seeking advice on how to set up this script in Ansys to ensure it works effectively. Are there any other considerations I should keep in mind when creating this script for Ansys?

Welding script

Hey everyone,
I'm new to this community and also new to coding in Ansys. I'm looking for help with creating a script to evaluate welds and avoid artificial stress concentrations, especially in corners.

Here's what I'd like the script to do:

**Inputs: **Provide the script with a predetermined path and the weld thickness in that area.
Functionality: The script should generate a stress graph using data from the path and identify the interval where the data is linear to create a line. I'd like an option bar to tweak the sensitivity formula for selecting data points to create the line, or have the ability to manually set the interval of data points.
Interpolation: From this line, the software should interpret the weld thickness and output the corresponding stress value at the weld location on the line.
Output: The script should produce a graph showing stress values along the path. It should also plot the created line for accuracy verification, with a marker to indicate the point of stress at the weld. Additionally, the graph should highlight the interval of data points used to create the line and mark the weld thickness on the axes. It should also add a note with the stress value at that weld thickens on the line. I'd like the option to number each data point (like 1, 2, 3, ...) to manually set the interval if that's easier.

I'm seeking advice on how to set up this script in Ansys to ensure it works effectively. Are there any other considerations I should keep in mind when creating this script for Ansys?

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Pernelle Marone-Hitz

First, you'll have to decide where you want the script to be executed :

in Mechanical : look into Mechanical Scripting and Mechanical DPF training material and documentation. Note that for creating a graph and reimporting in Mechanical you'll have to use a CPython subprocess as done here: Plot contact pressure along deformed edge - Community Forum
outside of Mechanical : look into PyDPF training and documentation.

Please also have a look at existing posts in this forum. Developing entire scripts is way outside the scope of this forum. Once you have started writing something, and have more specific questions, we'll be happy to help.

Stampe

Hey,

I'm hoping to execute the script in Ansys Mechanical if possible to make it as user friendly as possible.

I have an idea of how the script should look in Python, but I'm facing a couple of challenges.

First, I'm not sure how to extract data from the path and store it in a list in Python in mechanical so I can start processing it.

Another issue is that I haven't found any good examples on how to plot data in a graph after processing it.

I'm looking for information or examples that could guide me on these problems

Pernelle Marone-Hitz

If the result is created in Mechanical you could explore using PlotData to retrieve the data. There are some examples on the forum. To create the graph, you'll have to use the same method as I used in the example I provided above.

Stampe

Hey everyone,

I've just finished creating my Python scripts and set it up the way I want it to work.

However, I'm having trouble figuring out how to export data into a variable within the script. Despite searching, I haven't found any clear directions on how to do it.

I'm sure there are examples out there of people who've done this before, but I just can't seem to find them. Could anyone point me in the right direction?

Also, if you notice any potential issues with the script I'm planning to use, I'd appreciate any feedback or suggestions.

# This program plots measurement data and lets you:

# 1. Choose a section of the data to use for interpolation (a straight-line fit).

# 2. Extend (extrapolate) that line to zero and to a given weld thickness.

# 3. See the results on a plot and get the calculated stress values.


# --- Import the tools we need ---

import matplotlib.pyplot as plt   # Used for plotting graphs

import numpy as np                # Used for calculations (like fitting a line)


# ============================================================

# STEP 1: Load and clean the measurement data

# ============================================================


raw_data = """

0,	349,61

0,8571	410,99

1,7142	416,34

2,5713	377,62

3,4284	342,71

4,2855	319,57

5,1426	298,8

5,9997	283,72

6,8568	270,25

7,7139	259,99

8,571	250,74

9,4281	243,34

10,285	236,53

11,142	230,68

11,999	225,22

12,856	220,3

13,714	215,69

14,571	211,44

15,428	207,36

16,285	203,45

17,142	199,71

17,999	196,11

18,856	192,62

19,713	189,21

20,57	185,88

21,427	182,58

22,285	179,42

23,142	176,3

23,999	173,26

24,856	170,25

25,713	167,3

26,57	164,38

27,427	161,56

28,284	158,75

29,141	156,01

29,998	153,27

30,856	150,63

31,713	147,99

32,57	145,42

33,427	142,86

34,284	140,36

35,141	137,88

35,998	135,45

36,855	133,04

37,712	130,67

38,569	128,33

39,427	126,02

40,284	123,74

41,141	121,49

"""


# Convert the text data into numeric arrays

lines = raw_data.strip().split('\n')

x_vals, y_vals = [], []

for line in lines:

    line = line.replace(',', '.')

    parts = line.split()

    if len(parts) == 2:

        x, y = map(float, parts)

        x_vals.append(x)

        y_vals.append(y)

x_vals = np.array(x_vals)

y_vals = np.array(y_vals)


# ============================================================

# STEP 2: Show all data points and ask user to choose interval

# ============================================================


plt.figure(figsize=(10, 5))

plt.plot(x_vals, y_vals, marker='o', color='lightgray', label="Original Data")


# Label all points by index for user selection

for i, (x, y) in enumerate(zip(x_vals, y_vals)):

    plt.text(x, y, str(i), fontsize=10, ha='center', va='bottom', color='blue')


plt.title("Select Interval by Index (Blue Numbers)")

plt.xlabel("Distance [mm]")

plt.ylabel("Stress [MPa]")

plt.grid(True)

plt.legend()

plt.tight_layout()

plt.show()


# Ask user for interval and weld thickness

print("\nSelect the interpolation range using the blue indices on the plot:")

p1 = int(input(f"Enter start index (0–{len(x_vals)-1}): "))

p2 = int(input(f"Enter end index (0–{len(x_vals)-1}): "))

weld_thickness = float(input("Enter weld leg, (Distances between Root to Toe ) in [mm]: "))


if p1 > p2:

    p1, p2 = p2, p1


# ============================================================

# STEP 3: Fit a straight line to the chosen interval

# ============================================================


x_segment = x_vals[p1:p2+1]

y_segment = y_vals[p1:p2+1]


# Fit linear regression line (y = <?WORD FLAGGED?>*x + intercept)

coeffs = np.polyfit(x_segment, y_segment, 1)

<?WORD FLAGGED?>, intercept = coeffs

fit_line = np.poly1d(coeffs)


# Generate continuous x values (0 → last of segment)

x_full = np.linspace(0, x_vals[p2], 300)

y_full = fit_line(x_full)


# Find nearest actual data point to weld thickness

closest_index = np.argmin(np.abs(x_vals - weld_thickness))

x_cut = x_vals[closest_index]

y_cut = y_vals[closest_index]


# Find the maximum stress point in the original data

max_index = np.argmax(y_vals)

x_max = x_vals[max_index]

y_max = y_vals[max_index]


# ============================================================

# STEP 4: Plot everything together

# ============================================================


plt.figure(figsize=(10, 5))


# Plot original and selected points

plt.plot(x_vals, y_vals, 'o-', color='lightgray', label="Original Data", zorder=1)

plt.scatter(x_segment, y_segment, color='red', s=50, zorder=3, label='Used for interpolation')


# Plot fitted line (includes extrapolation)

plt.plot(x_full, y_full, '-k', linewidth=1.5, label='Extrapolated line', zorder=2)


# Mark vertical line at weld thickness

plt.axvline(weld_thickness, color='green', linestyle='--', label=f'Weld Toe = {weld_thickness:.2f} mm')

plt.text(weld_thickness+1, min(y_vals), f'{weld_thickness:.2f} mm', color='green', ha='left', va='bottom')

# === NEW: Mark intersection points ===

# Extrapolated intersection at 0 mm

plt.scatter([0], [fit_line(0)], color='purple', zorder=5, label='Extrapolated at 0 mm')

plt.text(0, fit_line(0), f"(0.00, {fit_line(0):.2f})", fontsize=9, color='purple', ha='left', va='bottom')


# Extrapolated intersection at weld thickness

plt.scatter([weld_thickness], [fit_line(weld_thickness)], color='darkgreen', zorder=5, label='Extrapolated at weld toe')

plt.text(weld_thickness, fit_line(weld_thickness), f"({weld_thickness:.2f}, {fit_line(weld_thickness):.2f})",

         fontsize=9, color='darkgreen', ha='left', va='bottom')


# Mark where weld thickness line meets original data

plt.scatter([x_cut], [y_cut], color='orange', zorder=5, label='Original data near weld toe')

plt.text(x_cut, y_cut, f"({x_cut:.2f}, {y_cut:.2f})", fontsize=9, color='orange')


# Mark the maximum stress point with a red star

plt.scatter([x_max], [y_max], color='red', marker='*', s=200, zorder=5, label='Maximum stress point')

plt.text(x_max, y_max, f"Max ({x_max:.2f}, {y_max:.2f})", fontsize=9, color='red', va='bottom')


# --- Show text box with results ---

results_text = (

    f"Extrapolated stress at weld toe ({weld_thickness:.2f} mm): {fit_line(weld_thickness):.2f} MPa\n"

    f"Extrapolated stress at 0 mm: {fit_line(0):.2f} MPa\n"

    f"Original data near weld thickness ({x_cut:.2f} mm): {y_cut:.2f} MPa"

)

plt.text(

    0.50, 0.50, results_text, transform=plt.gca().transAxes,

    fontsize=10, color='black', va='top',

    bbox=dict(boxstyle="round,pad=0.5", fc="white", ec="black", alpha=0.7)

)


# --- Final formatting ---

plt.title("Stress Distribution at Weld Toe")

plt.xlabel("Distance [mm]")

plt.ylabel("Stress [MPa]")

plt.legend()

plt.grid(True)

plt.tight_layout()

plt.show()


# ============================================================

# STEP 5: Print results in terminal

# ============================================================


print(f"\nFitted line equation: y = {<?WORD FLAGGED?>:.3f}x + {intercept:.2f}")

print(f"Extrapolated stress at 0 mm: {fit_line(0):.2f} MPa")

print(f"Extrapolated stress at weld thickness ({weld_thickness} mm): {fit_line(weld_thickness):.2f} MPa")

print(f"Original data value near weld thickness ({x_cut:.2f} mm): {y_cut:.2f} MPa")