Quality Diagnostics · D07
Adding a fillet radius cuts corner cracking by 80% - real drum-drop test data.
Corner Cracking
Failure Scenario
A part with through-holes, locating profiles, and various corners underwent drum-drop testing - every crack location matched a highlighted weld point from the Moldflow analysis.Root cause: corners are simultaneously a weld-line location (inherently lower strength) and a stress-concentration point (geometric discontinuity). The two risks stack, making corners the weakest region of the whole part.
Solution: add a fillet radius at the corner - this both increases local thickness and shifts the weld location away from the corner, into a lower-stress region. Verified result: corner cracking dropped 80% after the design change.
Full technical report → WP-04: Corner Design & Drop Reliability