I typically model fillet welds as small triangles.
In this case the fillet weld is along / across a sheet metal bend. As you can see this doesn't work out very well.
I talked to the sheet metal fabricator about what that type of weld actually looks like. He welded up a small sample and took a photo for me. The weld flowed down into the radius some but not very far. One option is to try and make a "radius" weld part to insert in there. Seems like that would cause me to guess at the depth the weld is going to flow down the radius. I can just make the triangle larger and have it span the two flats. Another option is to square off the sheet metal bend more but that seems to be adding a stress concentration that isn't really there.
The area in question is a high stress area so I would like to study it more closely.
I was wondering if anyone else has run across this and what they did.
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