I admittedly work in the world of solid elements 95% of the time, but I can't find a solution to this issue and would appreciate any input. I basically have a large box frame weldment consisting of c-channels and I-beams in an assembly (as surface parts). The frame is subject to large temperature gradients, and I am interested in the developed stresses, particularly at the joints. The thermal model runs fine and produces a reasonable temperature distribution. When I port that temp data into a shell-mesh static analysis, I am getting separation of I-beam flanges (within I-beam shell parts) at several points.

Attached is a single beam component subject to a representative temperature gradient and constraints. It, too, is separating along the web/flange interface. The problem happens with both thick and thin shell formulations. Also, at very high mesh density, my assembly produces NO stresses. Any thoughts?

Thanks for the help.

Brian

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