Hello everyone,

I am currently designing a roll cage for a project I'm working on.  Obviously, I've used the weldments tool with a 3D sketch to produce the bodies of the roll cage.  Most of it came out just fine, but the problem I've encountered comes with how the joints are actually modeled.  Some of them look like this:

That pointy tip at the bottom of the vertical tube cause lots of problems when I run it through ANSYS mechanical for FEA. The tip creates a high stress area because it assumes that those parts are welded together as such.  In reality, those points will be ground down (also to give more girth for welding - better weld joints).

Does anyone know how to make the corners rounder or insert weld beads that will actually cover that and mimic the rounding? I know how to use the weld bead tool, but the beads do not export to STEP since they are not technically part of the geometry.

Any help would be appreciated, thank you very much.

P.S.: Solidworks 2015