Chapter 14: Welded joints Two common types of welds namely but and filet welds are shown in Figure 1 Bus weld Filler weld Figure 1 Butt and filet welds Butt welds eis usually assumed that ‘+ Welds fllpenesration, thats ofthickessatleastequalto the unwelded plate. Also the ‘weld runs forthe full width ofthe unwelded plate ‘A welding rod has been used that asa strength a east equal to the unwelded plate, + Welding has been carried out by a competent trade welder andi in accordance with correct welding procedures for the materia! being welded. ‘Under these conditions a butt weld canbe assumed to ave strength t least equalto that of the unwelded plate. Infact, abut weld may betesedinatensile rbendtesting machine andit the Weld i @ good one, the plate should break before the weld. Design of butt welds ‘Withthe above assumptions, itis umecessaryto design abut weld separately fromthe plate and the assembly may be considered asa single continuous pat, Fillet welds ‘Thethxee assumptions above are aso treforafilet weldexcept thatthe size ofthe weldisot necessarily equal ta the size ofthe plate and maybe greater or lesser. Als the weld does nat necessarily run the fll width of the plat and flong welds are tobe made, tis preferable that they be intermittent rather then continuous. Notes + Whenspecifyng the length of fl weldit maybenecessary include anallowance {or starting end stopping the weld. However, thisis notasignificant factor unless the ‘weld is very short one and this allowance wil be ignored inthe examples given. + Fordesign purposes ifthe welds around a comerorcune, the thickness ofthe weld {snot taken nto account when calculating wed length, Forexample fe fillet weld were ‘made around a 20 mm square bar the Ingth ofthe weld would be taken as 80 mm. Si ‘Mechanical Design Dara Maal ma en caWelded Joints Chapter 14 ‘+ Thesize ofa filet weldis sways specified bythe eg lengths, not the throet thickness £ (Gefer Figure 1). For a standard iet weld, che angle of the weld is 45°, so: J 720.1078 + Preferred weld sizes (in mm) are 2,3,4, 5, 68,10, 12, 16 + Forlow carbonanmildstel plates, commonly usedelecric welding dis the B41. ‘This od hasa UTS of 410 MPa, For greater strength plates, an EA8xa rod (UTS 480 (Ma) is also commonlyased, + InFigure Lait weldhasteen shown on onlyone side ofthe vertcalplate. Thisis not idea and wherever possible, the Weld should be on both sides to minimise the weld Design of fillet welds Itiscustomary design practice to design filet weldsonthe assumption thatthe weld wilflin shear across the throat for any direction ofthe applied load. Since the welding rod should have astrengthat least equalto the plate the allowablestressinthe weldsthe allowable shea stress in the plate material, Noves + Underconditionsofstticor steady load, the allowable weldsuessisoftentakenas 0.3 XUTS,soifanELxxrodisused, the allowable stress wouldbe0.3x410 or 123 MPa and with an E48%xx rod, the allowable stress would be 144 MPa. + For dynamic or ey loads an appropriate design (safety) factor shouldbe apie, + Ifthe shear stress ofthe welding rod isnot known, a design rue-of thumb forsee! ‘welding isto use 75% of ce tensile strength ‘Two methods may be used forthe design of fet welds Conventional design method ‘The welds designed as a separate component, with sres area A=FL where = length of Weld. For applied load F (any direction), te stress inthe welds FE TE F = tas, Wat Weld asa line method Inthismethod, the weldis considered ss alinethtistohave no thickness. Thenthe ine stress {feted as Now eda ss a a Fe 9) an awWelded Joints hapten M4 Notes + Line stress fis not a tue stress, rather the force per mm length of weld ‘+ BothmethodsareilustratedinExample I, (page'315)butfromthen onthe line method will be used exclusively ‘+ Thelinerethod hasno advantage forthe design of simple filet welts, that is welds with direct loud only. However ts of great benefit whenthere are bending ortorsion ods con the weld Bending loads in fillet welds Consider fillet weld in bending as shown in Figure 2 Figure 2 File weld in bending ‘The conventional bending stress formula (for any bar or beam in bending) is M 1 Sy Me EE tote z= 1 che section modatus with units ma) TZ y Ifthe weld were not treated es «line, the second moment of area or the section modulus 2 would be ctferent with each diferent weld size. Ifthe weld size is unknoven this requires & ‘wiand-erro soltion. Using the weld es «ine method, a direct solution is possible using a ‘able of formulas forthe section modulus of various weld configurations such a in the table siven on page 314, The calculated bending stress then @lne stress, Note: Becanse the weld is treated as eine, the section modulus listed inthe table hes waits mt For the welded bar shown in Figure 2, there is als a direct line stress du tothe applied nad The inet line stress i 1 where. length of weld (inthis cate the perimeter of the bat) no aw ony DOEBRDUDNEMR RAR RRA asWelded Joints ‘These line stresses do not actin te same direction so they must be combined vectoraly to find the restitan. In tis case because the stresses are perpendicular to one another, the resultant ne stress fis fae +f ‘Torsion loads in fillet welds ‘The conventional torsional stress formula (for any bar or shaft in being) is rr f where adivs or distance from the centro to the outer fibre polar second moment of area ofthe section with unis mt [Ifthe weld isnot weated as line, then the same problem arises as with bending loads end J ‘would vary with each diferent weld size. Using the weld asa line method, a direct solution is possible using a table of formlas forthe polar moment of various weld coafigurations such ss in the table given on page 314. The calculated torsional sess is then a line stress Notes ‘+ Because the weld is treated asa line, the polar moment listed in the table has unite ‘+ ttere isa dec stress inthe weld tis will also nee to be combined vectoraly with the torsional stress to bean the resultant ine stress ay 99 313Welded Joints Chapter 14 Bending and torsion line stress formulas (see page 315 for method of lcsting C) (No_[ Diagram [2 ahout Gray [7 won 1 | 2 a q {| _ a E) tp E me ls id | Ragan | bd + 2 ted? 2/4 © :| OF ~ + s ae toa? ale er hn Alccm bd + dt Obs a? - Biba? Le @ Ged Pabsb s 560) bere - dbea? |_ [Te bottom 2 Gri) | @Qb+d > SO+d |b 2ae - dbear aie votom i2 +20) Spat d? 0 Grid |b + ale bottom Crd "6 bd + a? Bean? +a? 7 + oO 7 2hd + | ze + ood? +d? aE $ | 6 34 nanan TtWelded Joins hapten 14 Locating the centroid ‘The postion ofthe centroid of weld canbe calculated inthe save way as for any ees by breaking the area up int its components and then taking moments of each area about the equating this tothe total area moment (the total area multiplied by the conoid distance). That i fora horizontal reference axis (x axis) reference axis A + Ape + = Ay where isthe vertical centroidl distance ‘Treating the weld asa line, the weld canbe considered to be anarrow area of thickness 1 sum with no area moment about the narrow axis, Moments may then be taken a indicated above, For example, consider the L shaped weld shown in Figure 3 (Number 6 page 314) y s Ye Figure 3 ‘Making the reference x-x axis the weld length b, then », is the vertical distance below x-xto the centroid. “Taking moments about the xx axis dx Lx d= @+dx1x y (weld ength b hat no moment about xx) 2 Tera ‘Similarly taking moments about the y-y axis DxIx b= (O4a)x1x (weld length d_has no moment about y-3) 2 nee Tere Pebreny 1999 31s, aaWelded oi er 1a Forexample ifthe length of welds are: = 50mm and d= 30mm a = _ TErdh — TH+, 2 gStt = 15.625 mm Term ~ T5+3) ‘That is, the centroid of the Weld is located 5.625 mam down and 15.625 mm to the right 625 mm. Example 1 Direct load ‘The stel bar illustrated in Figure 4 is welded all round toa stel base plate, There is @ ‘rable load of maximum valuel0 KN acting vertically upward atthe centre ofthe bar. "The stool used has a yield point in tension of 220 MPa, A safety factor of3 i quired (on ye) [Determine the weld size required using (@ conventional stress analysis, (b) weld a a line method. Solution With a safety factor of 3, the design load is 30 KN, The yeld point i shear may be taken as 0.75 x 220 = 165 MPa (@) Conventional stress analysis tose 2mm weld ee Dea Dana noo ste por LRELELDELEAREAARARETATrAT tt AaaWelded Joins (8) Weld as a line method The line stress f = E_ =.30000 = 1339 Nimm 7 me -£ =1339 = 864mm (asabove) 1s oeiz ft. = 115mm ‘om se 2 mm weld Example 2. Weld in bending ( direct oad) Solve Example 1 by the weld at line method ifthe load act upward at 60° tothe vertical (hat is 30° to the horizonta, Solution ‘The desig load of 30 KN can be resolved into vertical and horizontal components. They are: F.=ISEN R.=25980N The direct line stents are Jo = 15000 = 67 Nim h 24 25980 = 116Nimm ae ‘The bending moment about the centroid ofthe weld is M-=25980 x80 = 2078 x10 Nimm From the table page 214, the applicable forma is formula 4 = bd +g? = 12x100 + 100% =4533 ma? $ 3 The line bending stress f M. = 2078 10! = 458.4 Nim (in a vertical direction) Zz 4833 The most highly stressed section isthe bottom left hand comer (the bending stress is maximum), ‘The line stresses hee are G24S84 467 =5954Nimm f= 116NimmWelded Joins Chapter 14 Combining vectorial 525 TE = 536 Nin 12538 =3.26mm 165 S= 326 = 46mm 0707 ‘So use $ mm weld [Example 3 Weld in torsion (+ direct load) ‘A 12 mm thick steel bars welded to a support plate with aS mm fillet weld as shown in Figur 5 Ik supports a steel cable acting at an angle of 30°. Ifthe stress inthe weld isnot to exceed 100 MPa, determine the maximum cable force F. 1 Figure 5 Solution ‘Rather then writing equations in terms ofthe force Fit is more convenient to assume a value {or F. After the stress calculations have been done, the assumed value for F can be makiplied bya factor to increase or decreas its" value by comparing the calculated stress tothe allowed So let F. HN=1000N- and F, = 1000 cos 60° = 866 N ‘The length of weld is: 100 + 2x 80 = 260 mm ‘The direct line stress is: f = 1000 =3.85 N/mm (at 60° downward from the horizontal) 260 ms Mec Den nt na oad 2Welded Joints Chapter 14 ‘To determine the torsional stress itis first necsssary to locate the centroid ofthe weld. Figure 6 ‘Taking moments sboot the y-y axis with B= 80 mm and d= 100 mam; 2x80x40 = 260. = 2462 mm ‘That is, te distance from C tothe edge ofthe support plate is: 80 24,62 = 55.38 mm ‘The torque (tuning moment) bout Cis : T= 866 x 155.38 = 134.6410? Ninn By inspection, the most highly stressed weld poston i tthe top REY comer (locato Figure 6) By trigonometry (See Figute 7): R= 746mm O= 47.9° Figure 7 aan 9 39Welded Joins Chapter 14 Using Forma 7, page 314 Je Obed? - bibed? 7 Gb+d Now 6=80mmand d= 160 mm J= 2608 - 30x 180 = 667x10% mn? 2 ‘The forsonal ine tress at point "sis fe TR = 16x 10'x 74.62 = 15.05 Nom 7 667x105 ‘The direct and torsional ne stresses ray now be combined vectorial 30 Figure 8 Using the cosine rule ff = 385% + 1505 -2x3,85x 15.05 cos 1679° = 188Nimm Now f= £. §_=5327MPa Tr 3x0707 Now the allowable weld sres is 100 MPa ‘Therefore the maximum applied force F =_J00_x1 = 18.8KN 3327 TET RRrEr rrr r rrr ra 7