In sheet metal bending parts, we often weld a simple gusset onto a bent bracket as shown in the figure below to increase its strength.
This structure itself does not have major issues, but introducing some optimizations can benefit both manufacturability and stress distribution. As seen from the model, the welding position requires manual measurement and positioning by the welder. Secondly, after welding, the load is primarily concentrated on the weld seams. Therefore, improvements can be made by addressing these two aspects.
The optimization method is quite straightforward: add two process notches on the bent bracket and two corresponding locating tabs on the gusset. This solves the two problems mentioned above.
The bent bracket with added notches is shown in the figure below.
The gusset with added locating tabs is shown in the figure below.
The fully assembled structure after the modification is shown in the figure below.
With this design, manual measurement and positioning are no longer required during welding; parts can be directly aligned and welded. Furthermore, the stress performance of the assembly is also improved. From a manufacturing standpoint, the additional workload for laser cutting is negligible, and the number of bending operations remains unchanged.
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